Energy Efficiency Training – Mozambique

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eTraining - Enhancing Energy Efficiency (EE) in Mozambique Energy Efficiency Training – Mozambique Thursday, 26 November 2020 Rahul Raju Dusa Senior Expert

Transcript of Energy Efficiency Training – Mozambique

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Energy Efficiency Training ndashMozambique

Thursday 26 November 2020

Rahul Raju DusaSenior Expert

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Scheduled Topics

Email rradudtudk

Day Module Topic12 November 2020 11 What is Energy Efficiency16 November 2020 13 EE Strategic Planning ndash Part 119 November 2020 14 Energy Audit and Management

24 November 2020 22Energy Audit and Management for Buildings

26 November 2020 25 Energy Efficiency - HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Energy Efficiency - HVAC

What Why

Where

When

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC system

Heating Ventilation and Air Conditioning System

Heating and cooling

equipmentCirculating

pumps

Fans and blowers

Cooling towers

Air Handling Units

Pipelines ducts and insulation

Others

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC systemHeating Ventilation and Air Conditioning system components

Mixed-air plenum and outdoor air

controlAir filters Supply fan Exhaust fan Outdoor air intake

Ducts Terminal devices Return air system Heating and cooling coils

Self contained heating or cooling

unit

Cooling tower Boiler Control system Chiller unitsHumidification and dehumidification

equipment

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Scheduled Topics

Email rradudtudk

Day Module Topic12 November 2020 11 What is Energy Efficiency16 November 2020 13 EE Strategic Planning ndash Part 119 November 2020 14 Energy Audit and Management

24 November 2020 22Energy Audit and Management for Buildings

26 November 2020 25 Energy Efficiency - HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Energy Efficiency - HVAC

What Why

Where

When

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC system

Heating Ventilation and Air Conditioning System

Heating and cooling

equipmentCirculating

pumps

Fans and blowers

Cooling towers

Air Handling Units

Pipelines ducts and insulation

Others

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC systemHeating Ventilation and Air Conditioning system components

Mixed-air plenum and outdoor air

controlAir filters Supply fan Exhaust fan Outdoor air intake

Ducts Terminal devices Return air system Heating and cooling coils

Self contained heating or cooling

unit

Cooling tower Boiler Control system Chiller unitsHumidification and dehumidification

equipment

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Energy Efficiency - HVAC

What Why

Where

When

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC system

Heating Ventilation and Air Conditioning System

Heating and cooling

equipmentCirculating

pumps

Fans and blowers

Cooling towers

Air Handling Units

Pipelines ducts and insulation

Others

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC systemHeating Ventilation and Air Conditioning system components

Mixed-air plenum and outdoor air

controlAir filters Supply fan Exhaust fan Outdoor air intake

Ducts Terminal devices Return air system Heating and cooling coils

Self contained heating or cooling

unit

Cooling tower Boiler Control system Chiller unitsHumidification and dehumidification

equipment

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ119864119864119877119877119877119877 119864119864119864119864119875119875119877119877119903119903119864119864119903119903 (119896119896119896119896)119873119873119864119864119877119877 119864119864119864119864119864119864119864119864119864119864119864119864 119880119880119880119880119904119904119904119904119880119880119864119864 119864119864119864119864119877119877119875119875 119864119864119890119890119877119877119864119864119864119864119864119864119877119877119880119880 119880119880119877119877119880119880119864119864119864119864119864119864119880119880 (119896119896119896119896)

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC system

Heating Ventilation and Air Conditioning System

Heating and cooling

equipmentCirculating

pumps

Fans and blowers

Cooling towers

Air Handling Units

Pipelines ducts and insulation

Others

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC systemHeating Ventilation and Air Conditioning system components

Mixed-air plenum and outdoor air

controlAir filters Supply fan Exhaust fan Outdoor air intake

Ducts Terminal devices Return air system Heating and cooling coils

Self contained heating or cooling

unit

Cooling tower Boiler Control system Chiller unitsHumidification and dehumidification

equipment

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC system

Heating Ventilation and Air Conditioning System

Heating and cooling

equipmentCirculating

pumps

Fans and blowers

Cooling towers

Air Handling Units

Pipelines ducts and insulation

Others

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC systemHeating Ventilation and Air Conditioning system components

Mixed-air plenum and outdoor air

controlAir filters Supply fan Exhaust fan Outdoor air intake

Ducts Terminal devices Return air system Heating and cooling coils

Self contained heating or cooling

unit

Cooling tower Boiler Control system Chiller unitsHumidification and dehumidification

equipment

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC system

Heating Ventilation and Air Conditioning System

Heating and cooling

equipmentCirculating

pumps

Fans and blowers

Cooling towers

Air Handling Units

Pipelines ducts and insulation

Others

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC systemHeating Ventilation and Air Conditioning system components

Mixed-air plenum and outdoor air

controlAir filters Supply fan Exhaust fan Outdoor air intake

Ducts Terminal devices Return air system Heating and cooling coils

Self contained heating or cooling

unit

Cooling tower Boiler Control system Chiller unitsHumidification and dehumidification

equipment

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

What is HVAC systemHeating Ventilation and Air Conditioning system components

Mixed-air plenum and outdoor air

controlAir filters Supply fan Exhaust fan Outdoor air intake

Ducts Terminal devices Return air system Heating and cooling coils

Self contained heating or cooling

unit

Cooling tower Boiler Control system Chiller unitsHumidification and dehumidification

equipment

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ119864119864119877119877119877119877 119864119864119864119864119875119875119877119877119903119903119864119864119903119903 (119896119896119896119896)119873119873119864119864119877119877 119864119864119864119864119864119864119864119864119864119864119864119864 119880119880119880119880119904119904119904119904119880119880119864119864 119864119864119864119864119877119877119875119875 119864119864119890119890119877119877119864119864119864119864119864119864119877119877119880119880 119880119880119877119877119880119880119864119864119864119864119864119864119880119880 (119896119896119896119896)

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Why HVAC system

Source IEA (2018) Energy Efficiency 2018 httpswwwieaorgefficiency2018

Energy efficiency investment in buildings by subsector and end use 2017

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Number of energy conservation proposals

46

31

23

Payback period (Returns)

Short term

Medium term

Long term

9

20

33

8

9

5

16

Component shareElectrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

bull Payback period = Total investment Annual Energy Savings bull Short term (lt 1year) Medium term (1-3 years) Long term (gt3 years)

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy savings

5633

11

Payback period

Short term

Medium term

Long term

16 6

405

22

38

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Area-wise share of energy cost savings

5829

13

Payback period

Short term

Medium term

Long term

14

8

57

6

1

410

Component share

Electrical systems

Electrical drives

HVAC

Other Pumping andcooling towers

Boiler and steam

Compressed air

Lighting

Note Representing climatic zones ndash Hot and DryWarm and HumidCompositeModerateTropicalRepresenting building types Educational Institutional Assembly Business Industrial Storage Merchantile

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and Where

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Source BEE India

Air-conditioning Refrigeration

Heating humidifying and control of air quality

Cooling and dehumidifying operations in air conditioning

Industrial refrigeration including food preservation chemical and process industries

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

When and where do we need HVAC systems

Comfort air conditioning (200C-250C)

Process cooling ndash chilled water system (80C-100C)

Brine systems (sub-zero applications)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How

How HVAC system works

How we assess energy efficiency performance

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How HVAC system works

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash cooling and air conditioning

HVAC system -Cooling

Vapor compression

system

Vapor absorption

systemEvaporative

cooling system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Source BEE India

Air cooled system (small capacities DX type)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged terminal air-conditioner or heat pump

Window air-conditioner

Non-ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Air cooled system (small capacities DX type)

Packaged ducted AC or heat pump Ducted split system AC or heat pump

Source Domestic Air Conditioner Test Standards and Harmonization IEA 2020

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Air cooled system

Source Trane air cooled chiller

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system ndash Heat transfer loops

Water cooled system

Source 1 HVAC and Refrigeration system Bureau of Energy Efficiency India2 Hudson Technologies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ119864119864119877119877119877119877 119864119864119864119864119875119875119877119877119903119903119864119864119903119903 (119896119896119896119896)119873119873119864119864119877119877 119864119864119864119864119864119864119864119864119864119864119864119864 119880119880119880119880119904119904119904119904119880119880119864119864 119864119864119864119864119877119877119875119875 119864119864119890119890119877119877119864119864119864119864119864119864119877119877119880119880 119880119880119877119877119880119880119864119864119864119864119864119864119880119880 (119896119896119896119896)

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression systemHeat sink (High temperature level)

Condenser

Cooling Tower

Evaporator

AHUHeat Source (Low temperature level)

CompressorMotor

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour compression system

Parameters Reciprocating Centrifugal Screw1Refrigeration temp Range(Brinewater)

+7 to -30degC +7 to 0degC +7 to -25degC

2Sp Power consumptionbull Air conditioningbull Sub zero temp

07ndash09 kWTR 12ndash25 kWTR

059ndash063 kWTR 065ndash07 kWTR 125ndash25 kWTR

3Refrigerant (For complete list)

R11 R123 R134A Ammonia

R22 R12 R22 R134A Ammonia

4Typical single unit capacitybull Air conditioningbull Sub zero temp

Upto 150 TR 10-50 TR

250 TR amp above 50-250 TR 50-200 TR

Comparison of different types of vapor compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ119864119864119877119877119877119877 119864119864119864119864119875119875119877119877119903119903119864119864119903119903 (119896119896119896119896)119873119873119864119864119877119877 119864119864119864119864119864119864119864119864119864119864119864119864 119880119880119880119880119904119904119904119904119880119880119864119864 119864119864119864119864119877119877119875119875 119864119864119890119890119877119877119864119864119864119864119864119864119877119877119880119880 119880119880119877119877119880119880119864119864119864119864119864119864119880119880 (119896119896119896119896)

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Vapour Absorption system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types of VAMParameter Single Double Half Triple Single (Ammonia)

Refrigeration temp (0C)

Above 60C Upto -330C

Energy input (Heat)

SteamHot WaterHot

OilDirect fired

SteamHot WaterHot OilDirect fired

Hot WaterSteamHot

OilDirect firedSteamHot

WaterHot Oil

Min heat input temp (0C )

85 130 55 190 85

Energy to TR ratio (kcalTR)

5000 2575 7500 2000 4615

Refrigerant Pure water Pure Ammonia

Absorbent Water-LiBr solutionAmmonia ndash LiBr

solutionAir conditioningrange (TR)

ge30 ge30 ge30 ge50 ge30

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

VCM vs VAM

VCM VAM

Energy inputElectricity for compressor motor

Electricity for two small circulating pumpsonly

Primary input heat energyCOP 4 to 5 for AC applications Low 11 (for 2-stage LiBr machines)Heat rejection factor

12 25 (very high ndash higher CT and pumpcapacity required)

Life span Relatively high Relatively low (LiBr is corrosive in nature)

Use VAM only if you have waste heat or cheaper fuel source

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Evaporative cooling

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglxswD85XiP4UNfFEY6

Simple solar thermal system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgoogl3QjZFGT8zZaF1Wv29

Boilers (gas electrical oildiesel etc)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglbqnbZ3KJTxAVb1927

Solar thermal + boiler integrated system

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglvDayAimQhbTCKdcD6 httpsimagesappgooglwkreCM6XqTJSeucX8

Heat pumps

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Heating

Source httpsimagesappgooglRrZHcrqm9A2uktWM7 httpsimagesappgooglC3q9LHN1FwBdoxKt6

Electrical resistance heaters

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ119864119864119877119877119877119877 119864119864119864119864119875119875119877119877119903119903119864119864119903119903 (119896119896119896119896)119873119873119864119864119877119877 119864119864119864119864119864119864119864119864119864119864119864119864 119880119880119880119880119904119904119904119904119880119880119864119864 119864119864119864119864119877119877119875119875 119864119864119890119890119877119877119864119864119864119864119864119864119877119877119880119880 119880119880119877119877119880119880119864119864119864119864119864119864119880119880 (119896119896119896119896)

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Ventilation

Source BEE India

Centrifugal Axial

Radial High pressure Medium flow

Industrial applications Propeller Low pressure

high flow

Air circulation ventilationexhaust

Forward curved

Medium pressure high flow

Low pressure HVAC packagedunits clean environment

Tube-axialMedium pressure high flow

HVAC exhaust systems ovens

Backward curved

High pressurehigh flow

HVACindustrial applications

Vane-axial High pressure medium flow

High pressure applications HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types - Pumps

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ119864119864119877119877119877119877 119864119864119864119864119875119875119877119877119903119903119864119864119903119903 (119896119896119896119896)119873119873119864119864119877119877 119864119864119864119864119864119864119864119864119864119864119864119864 119880119880119880119880119904119904119904119904119880119880119864119864 119864119864119864119864119877119877119875119875 119864119864119890119890119877119877119864119864119864119864119864119864119877119877119880119880 119880119880119877119877119880119880119864119864119864119864119864119864119880119880 (119896119896119896119896)

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Types ndash Cooling towers

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How we assess efficiency performance

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Measurements of HVAC systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ119864119864119877119877119877119877 119864119864119864119864119875119875119877119877119903119903119864119864119903119903 (119896119896119896119896)119873119873119864119864119877119877 119864119864119864119864119864119864119864119864119864119864119864119864 119880119880119880119880119904119904119904119904119880119880119864119864 119864119864119864119864119877119877119875119875 119864119864119890119890119877119877119864119864119864119864119864119864119877119877119880119880 119880119880119877119877119880119880119864119864119864119864119864119864119880119880 (119896119896119896119896)

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR)

A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0degC

1 TR = 3024 kcalhour = 351 kW = 12000 BTUhour

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

1 TR = 12119864119864119864119864119864119864119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864 119877119877119877119877119877119877119864119864119877119877 (119864119864119864119864119877119877)

= 3516119862119862119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 119875119875119864119864119864119864119864119864119877119877119864119864119875119875119877119877119864119864119864119864119864119864 (119862119862119862119862119875119875)

Coefficient of Performance COP = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 119877119877119864119864 ℎ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

Energy Efficiency Ratio EER = 119880119880119880119880119864119864119864119864119880119880119880119880 119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119864119864119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119861119861119861119861119861119861ℎ119900119900119900119900119900119900)

119896119896119877119877119864119864119896119896 119903119903119877119877119864119864119864119864 (119896119896)

Specific Power Consumption SPC = 119875119875119877119877119875119875119864119864119864119864 119864119864119877119877119864119864119880119880119880119880119875119875119904119904119877119877119864119864119877119877119864119864 (119896119896119896119896)119877119877119864119864119864119864119864119864119864119864119864119864119864119864119864119864119877119877119877119877119864119864119877119877119864119864 119864119864119864119864119864119864119864119864119864119864119877119877 (119879119879119877119877)

Efficiency ratios

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

CHW supply T

CHW return T

CDW inlet T

CDW inlet T

CDW flow rate Compressor motor input kW

CHW flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Chiller

TR = (flow rate (kgh) x specific heat (kcalkg0C) x diff Temp degC)3024

Cooling coil

TR= ( air flow (m3h) X density (kgm3) X diff H (kcal x kg))3024

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

bull Screw chiller 250 TRbull Chilled water flow rate 42 lpsbull Inlet water temperature 122degCbull Outlet water temperature 72degCbull Refrigeration capacity

Power consumption 4032 kW

Specific power consumption 4032250

119896119896119896119896119879119879119877119877

= 062 119896119896119896119896119879119879119877119877

120786120786120786120786 times 120785120785120785120785120785120785120785120785 times 120783120783 times (120783120783120786120786120786120786 minus 120789120789120786120786)120785120785120785120785120786120786120786120786 = 120786120786120784120784120785120785 119931119931119931119931

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Chiller performance testing

Cooling load estimation

bull Small office cabins - 01 TRmsup2

bull Medium size office - 006 TRmsup2

bull Large multi-storeyed office - 004 TRmsup2

Note for indicative purpose only Cannot be taken as a basis for any investment grade activities

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Water flow rate

Pump motor input kW

Pump head

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump Efficiency =

Hydraulic Power Ph (kW) = Q X (Hd ndash Hs) X ρ X g1000

Q = Volume flow rate (m3s)

ρ = Density of fluid (kgm3)

g = Acceleration due to gravity (ms2)

Hd = Discharge pressure (meter)

Hs = Suction pressure (meter)

Power Input to the pump shaft = Drive input power X Motor efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump efficiency

Pump operating parameters

Q = 350 m3h ρ = 1000 kgm3 g = 981ms2

Discharge pressure = 30 meter

Suction pressure = 3 meter

Total Head = (30 ndash 3) = 27 meter

Input Power = 35kW

Motor efficiency = 92

Pump η =

Pump η = 80

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Pump performance testing

Pump performance curve

Q = 214 m3h

H = 616 m

P = 52 kW

Pump efficiency = 73

3

2

1

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

ρ2=ρ1 times1198791198791

1198791198792times1198751198751

1198751198752

ρ Density kgm3

P Pressure mm Wg (kgm2)T Temperature KelvinSuffix -1 represents parameters at NTP ρ1= 129 kgNm3

P1= 1 bar = 10330 mm wgT1= 0 oC = 273 K

Suffix ndash 2 represents measured parameters at sample point

Velocity 119881119881 = 119862119862 times 2times119864119864timesℎρ

WhereC Pitot factorg Acceleration due to gravity 981 ms2

h Dynamic pressure mm Wg (kgm2 )r Density at sample point kgm3

If the inlet side is not ducted then the velocity can be obtained directly by using an Anemometer

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Fan amp Blower performance testing

Source BEE India

Flow Q m3s = A x V

A= cross sectional area (m2) 120587120587times119863119863119880119880119864119864119877119877 1199031199031198641198641198771198771198751198751198641198641198771198771198641198641198641198642

4or height x width

V = Velocity (ms)

Air Horse power kW = Q x ∆Pt x g1000

Q Flow in m3 secH Head in m ∆Pt Total pressure rise in mm wg (kgm2)g Acceleration due to gravity 981ms2

Shaft Horse Power (SHP) kW = Motor input power kW x ɳ motor

(ɳ motor = Efficiency of motor)

Fan efficiency ɳ = 119912119912119912119912119912119912119930119930119912119912119912119912

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

Leaving air DBTRH

Entering air DBTRH

Water flow rate

Entering water T

Leaving

water T

Fan motor input kW

Air flow rate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Cooling tower performance testing

119877119877119877119877119877119877119877119877119877119877 = 119879119879 ℎ119900119900119900119900 minus 119879119879 119888119888119900119900119888119888119888119888

119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ = 119879119879 119888119888119900119900119888119888119888119888 minus 119879119879 119908119908119877119877119900119900 119887119887119887119887119888119888119887119887

119864119864119864119864119864119864119877119877119888119888119900119900119864119864119864119864119877119877119877119877119877119877119864119864119864119864 =119877119877119877119877119877119877119877119877119877119877

119877119877119877119877119877119877119877119877119877119877 + 119860119860119860119860119860119860119860119860119900119900119877119877119888119888ℎ

119864119864119864119864119877119877119860119860119900119900119860119860119877119877119900119900119864119864119900119900119877119877 119888119888119900119900119864119864119864119864119898119898119898ℎ119860119860

= 000085 times 18 times 119888119888119864119864119860119860119888119888119887119887119888119888119877119877119900119900119864119864119900119900119877119877 119860119860119877119877119900119900119877119877 (119898119898119898ℎ119860119860

)times (119879119879119864119864119877119877 minus 119879119879119900119900119887119887119900119900)

Source BEE India

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU Performance testing

Fan motor input kW

CHW Outlet T

Supply air DBTRH Return air DBTRH

Air flow rate

CHW inlet T

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

Inlet air flow 21665 msup3h (602 msup3s)

Entering air 242degDBT 172 degC WBT 515 RH

Entering air enthalpy 52 kJkg

Leaving air 140degDBT 125 degC WBT 85 RH

Leaving air enthalpy 38 kJkg

Entering air density 105 kgmsup3

Tons of refrigeration 21665 times 105 times (52minus38)(3024times418)

= 252 119879119879119877119877

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

AHU package DX unit performance testing

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Heat pump performance testing

119862119862119862119862119875119875 =119876119876 119887119887119864119864119877119877119864119864119887119887119888119888 ℎ119877119877119877119877119900119900119876119876 119877119877119888119888119877119877119888119888119900119900119860119860119864119864119888119888

If a heat pump releases 4 kW of heat and consumes 1 kW of electric power then

119862119862119862119862119875119875 =41198961198961198961198961 119896119896119896119896

= 40

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Boiler performance testing

Parameters to be monitored bull Quantity of steam generated per hour (Ms) in kgh

bull Quantity of fuel used per hour (Qc) in kgh

bull Working pressure (in kgcm2(g)) and steam

temperature (o C) corresponding enthalpy (Hs) in

Kcalkg

bull The temperature of feed water (o C) and

corresponding enthalpy (Hf) in kcalkg

bull Type of fuel and gross calorific value of the fuel

(GCV) in kcalkg of fuel

119861119861119900119900119864119864119888119888119877119877119860119860 119877119877119864119864119864119864119864119864119888119888119864119864119877119877119877119877119888119888119890119890(η) = 119867119867119864119864119877119877119877119877 119877119877119880119880119877119877119904119904119880119880119877119877119867119867119864119864119877119877119877119877 119864119864119864119864119904119904119880119880119877119877

times 100

= 119867119867119864119864119877119877119877119877 119864119864119864119864 119880119880119877119877119864119864119877119877119875119875 119877119877119880119880119877119877119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)119867119867119864119864119877119877119877119877 119864119864119864119864 119864119864119880119880119864119864119880119880 119864119864119864119864119904119904119880119880119877119877 (119896119896119864119864119877119877119880119880119880119880)

times 100

= 119872119872119880119880times(119867119867119880119880minus119867119867119864119864)119876119876119864119864times119866119866119862119862119866119866

times 100

Example 6000119896119896119877119877ℎ times 662 minus 1198982 119896119896119888119888119877119877119888119888

119896119896119877119877

1200 119896119896119877119877ℎ times 491198980119896119896119888119888119877119877119888119888119896119896119877119877

times 100 = 61198989

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

How to save energy

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Follow best energy labelling standards available

bull User of inverter integrated products

bull Maintenance of heat exchanger surfaces (evaporator condenser cooling coils)bullbull Matching capacity to system load

bull Capacity control

bull Chilled water storage

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Economic insulation thickness - cold insulation

bull Adoption of roof coatingsfalse ceilingsun control films

bull Adoption of variable air volume (VAVrsquos)air curtains

bull Adoption of pre-cooling fresh air optimum no of air changes

bull Reducing heat loads in conditioned space

bull Heat recovery units and recuperators

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

Parameters Reciprocating Centrifugal ScrewCapacity controls onoff (small) Inlet guide vane

(IGV) Slide valve

Unloading of cylinders

Variable speed drive with IGV

Variable speed drive Suction throttling

Typical COP at part load upto 50

Reduces at part load

Reduces at part load

Improves by 15 ndash20

Capacity control types for vapour compression systems

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

bull Least count of thermocouples to be used - 01degCbull In generalchilled water flow - 068 msup3h per TR (3 gpmTR)Condenser water flow - 091 msup3h per TR (4 gpmTR)

bull A reduction of 055degC temperature in water returning from the cooling tower reduces compressor power consumption by 3

bull A 1degC raise in evaporator temperature can help to save almost 3 on power consumptionbull Lowest possible cooling tower water should be passed through chillersbull Leaving water temperature (Evaporator) should be monitored (most of the cases)

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash air conditioning and refrigeration

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Pumps Fans and blowersbull Avoid oversizing

bull Change of impeller by high efficiency impeller

bull Replacing with high efficiency equipment

bull Impeller de-rating (by a smaller dia impeller)

bull Speed reduction by pulley dia change (for fans and blowers)

bull Options for energy efficient flat belts in place of V-belts (for fans and blowers)

bull Adopting Inlet guide vanes in place of damper control (for fans and blowers)

bull Minimizing system resistance and pressure drops

bull Variable speed drive variable speed fluid coupling application

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersDamper change Inlet Guide Vanes

Control mechanisms

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures ndash Fans and blowersCentrifugal Fans Peak Efficiency Range

Airfoil backward curvedinclined 79-83

Modified radial 72-79Radial 69-75

Pressure blower 58-68Forward curved 60-65

Axial fanVanaxial 78-85Tubeaxial 67-72Propeller 45-50

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

bull Avoid electric resistance heaters bull If electricity is the only choice heat

pumps are preferable in most climates - they easily cut electricity use by 50 when compared with electric resistance heating

bull Insulation of pipes and equipmentbull Installation of thermostatic regulators on

radiatorsbull Install balancing valvesbull Energy metering and monitoring

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Source httpswwwuneceorgfileadminDAMenergysepdfsgeeestudyFinal_Master_file_-_March_11_final_submissionpdf

Boilersbull Optimal stack temperatures

bull Encourage feed water preheating (economizer solar thermal or heat pump integration)

bull Avoid incomplete combustion

bull Excess air control

bull Minimize surface radiation and convection losses

bull Use of condensing boilers

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

EE measures - Heating

Sourcehttpswwwenergygovenergysaverhome-heating-systemsfurnaces-and-boilers

Boilers (residential and commercial buildings)

Old low efficiency Mid-efficiency High ndash efficiencyNatural draft Exhaust fan controls for

combustion air and gasesCondensing flue gases in second heat exchanger for extra efficiency

Heavy heat exchanger Electronic ignition Sealed combustion56 - 70 AFUE Compact and light weight 90 to 985 AFUE

Small dia flue pipe80-83 AFUE

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Part 2Case studies

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 1 Adopting VRF systemsBackground bull About 10 DX duct type individual ACs with total capacity of 555TR installed bull Very old and deteriorated condition

Recommendation bull Replace with VRF systems

Savings Annual energy savings for just 10 hours of daily operation 59103 kWhPayback lt 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDFacility description

Parameter Unit DetailsMake TRANETYPE Helio-rotory compressorModel RTHD UC2U (C2F2F3)Capacity TR 250Refrigerant - R-134 AChilled water flow m3hr Min 90 Max 4032 (3 pass

evaporator)Chilled water inlet outlet temperature

0C 12 65

Condenser water flow m3hr Min 792 Max 3852 (2 pass evaporator)

Rated power kW 168

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDHourly energy consumption trend (kWhhour) for Chiller 1 and 2 for 24 hours

duration

00200400600800

10001200140016001800

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

000

000

00

Ener

gy co

nsum

ptio

n k

Wh

CH1 kWh CH2 kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 2 Chiller operations with VFDSpecific Power Consumption (SPC) and Cooling load details comparison of Chiller 1 (VFD) and Chiller 2 (non-VFD)

000200040006000800010000120001400016000180002000022000

0010203040506070809

0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

Cool

ing

Load

TR

Spec

ific

Pow

er C

onsu

mpt

ion

(kW

TR)

Time

Chiller 1 VFD Cooling load Chiller 2 non VFD Cooling loadChiller 1 VFD SPC Chiller 2 non VFD SPC

Annual energy savings with VFD 22 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operationsProvide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Background Cooling tower fans operated at full speed irrespective of climatic condition (ambient temperature) and cooling tower leaving water temperature Set cut-off point at 240C

Particulars Unit ValueCooling tower outlet water temperature

OC 297

Cooling inlet water temperature OC 33Ambient wet bulb temperature OC 2583Range OC 33Approach OC 387Cooling tower effectiveness 460Circulation water flow rate m3h 429Total Heat Rejection TR 468CT fan Power kW 293

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 3 Optimize cooling tower operations

Provide VSD for main cooling tower fans and operate with fans drive with cooling tower leaving water temperature

Recommendation bull Cut-off set point to be regularly changed wrt WBTbull Install VSD for CT fans with CWLT feedback for dynamic control

Savings

043 Lakh kWhannum 05 year payback

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures bull 2 Chillers x 1000 TR (4 amp 6) in parallel operation

bull VFD for compressor CHW and CW pumps

bull Online flow meters (ultrasonic) available ndash yet deviation from design parameters

bull One CHW pump with VSD while another pump with DOL operation

bull Even the orientationindication of pumps in DCS logic system is indicating wrongly

bull Rectified cooling water valves which was earlier throttled to chiller 4

bull Post investigation team had reduced the set point (2 PSI on each trials) for Cooling water pumps to optimize the pressure drop across the system and thereby improve operational efficiency

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 4 Rectify system flows and pressures Particulars Unit Before AfterChiller 4SPC kWTR 0617 0444COP kWkW 569 79Chiller 6SPC kWTR 0533 0459COP kWkW 659 765

Annual energy savings achieved 63 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 5 Use VAM bull Facility had 2 x 1000TR centrifugal chillers and 2 x 545 TR VAM

bull Hot water source at 160-180 0C available

bull Assessments were done and recommended to prioritize VAM operations to cater to the

cooling loads

bull The chillers used as back-up

Annual energy savings achieved 144 Lakh kWh

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Stop using VAM Background bull 500 TR VAM consuming bio-diesel 160 ndash 170 lph ($ 07 to $ 08 per litre) for

bull Going green Reliability Challenges in getting approval for higher contract demand at the commissioning stage

bull 35 to 40 loading

Recommendation bull 250 TR two compressor water cooled screw chiller to be installed bull For green energy opt for RE certificates wheeling PPA agreements of RE or install solar

panels

Savings $ 027 million per annum worth fuel and power savings Payback 05 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHUTechnology up gradation to Electronically Commutated (EC) fan motors for the AHUs

Backgroundndash Pluggedpulley type driven fan motors at present with VFDndash Frequencies set either auto or manual mode operation ndash Based on user side pressure requirements

Recommendationndash Convert to direct coupled DC based brushless EC motor driven fansndash Improved performance higher efficiency compact and reliable

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 Technology upgradation - AHU

Conventional motor-fan with VFD EC motors

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 6 Technology upgradation - AHUS No AHU Name Actual Before Actual After SavingRating KW After Rating KW KW CFM KW CFM

1 Ahu-4 15 12 938 7791 464 7810 512 Ahu-1 15 12 922 11456 506 11520 453 Ahu-8 75 6 596 5456 236 5490 604 AHU 2 11 15 95 23150 531 23985 445 AHU 3 75 68 622 18207 4 18613 366 AHU 5 15 15 1281 27968 85 25580 347 AHU 6 15 15 1501 18681 93 18735 388 AHU 7 11 12 552 8132 275 8875 509 AHU 9 11 102 706 8213 358 8522 49

10 QA 12 11 10 1009 9667 469 10894 5411 Warehouse-G 15 15 1206 17555 634 17980 4712 Warehouse-F 15 15 131 15993 686 16025 48

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 7 InsulationBackground

bull 70C temperature rise between generation and user end bull Close to 25 TR loss

Recommendation bull Tank and pipeline insulation to be maintained

Savings

$ 27000 per annum Payback 1 year

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 8 Air loss through stand-by blowers

Annual energy Savings 021 lakh kWh

Payback -Immediate

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 9 Boiler performance improvement ndashclean tubes

Background bull 3 TPH 1035 kgcm2 pressure rated diesel fired boiler in hotelbull Operating efficiency of 818 - lowbull Majore heat loss through flue gas (106)bull Soot built up on tubes ndash leads to poor heat transfer

Recommendation bull Tubes to be cleaned and stack temperature monitored on regular basis

Savings 265 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Case 10 Use of Heat pumpsBackground

bull Diesel fired boilers used for hot water generation in a hotelbull Cityrsquos location weather highly suitable for heat pump installationbull The diesel fuel high cost also supported the change

Recommendation bull Heat pumps to be installed bull Existing boiler may be used for back up

Savings 135 kL annual diesel savings

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92

eTraining - Enhancing Energy Efficiency (EE) in Mozambique

Thank YouEmail rradudtudk

Be the change you want to see in the world

  • Slide Number 1
  • Scheduled Topics
  • Energy Efficiency - HVAC
  • Part 1
  • What
  • What is HVAC system
  • What is HVAC system
  • Why
  • Why HVAC system
  • Number of energy conservation proposals
  • Area-wise share of energy savings
  • Area-wise share of energy cost savings
  • When and Where
  • When and where do we need HVAC systems
  • When and where do we need HVAC systems
  • How
  • How
  • How HVAC system works
  • Types ndash cooling and air conditioning
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Air cooled system (small capacities DX type)
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system ndash Heat transfer loops
  • Vapour compression system
  • Vapour compression system
  • Vapour Absorption system
  • Types of VAM
  • VCM vs VAM
  • Evaporative cooling
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Heating
  • Types - Ventilation
  • Types - Ventilation
  • Types - Pumps
  • Types ndash Cooling towers
  • How we assess efficiency performance
  • Measurements of HVAC systems
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Chiller performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Pump performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Fan amp Blower performance testing
  • Cooling tower performance testing
  • Cooling tower performance testing
  • AHU Performance testing
  • AHU package DX unit performance testing
  • AHU package DX unit performance testing
  • Heat pump performance testing
  • Boiler performance testing
  • How to save energy
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash air conditioning and refrigeration
  • EE measures ndash Pumps Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures ndash Fans and blowers
  • EE measures - Heating
  • EE measures - Heating
  • EE measures - Heating
  • Part 2
  • Case 1 Adopting VRF systems
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 2 Chiller operations with VFD
  • Case 3 Optimize cooling tower operations
  • Case 3 Optimize cooling tower operations
  • Case 4 Rectify system flows and pressures
  • Case 4 Rectify system flows and pressures
  • Case 5 Use VAM
  • Case 6 Stop using VAM
  • Case 7 Technology upgradation - AHU
  • Case 7 Technology upgradation - AHU
  • Case 6 Technology upgradation - AHU
  • Case 7 Insulation
  • Case 8 Air loss through stand-by blowers
  • Case 9 Boiler performance improvement ndash clean tubes
  • Case 10 Use of Heat pumps
  • Slide Number 92