Energy Efficiency Training – Mozambique
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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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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