Title: Optimization of Central Air-conditioning Chillers System
Team:Leader: Joselito MendezAssistant: Oscar RomanMembers: Manny Mabalot
George Villamor Gabriel Custodio - BCC Jojo Placer – Trane Philippines
Champion: Chatiya Nantham
Project No. OAS-06-003 (2W)
The operation of air-conditioning is the largest energy user in ADB HQ utilizing about 44% of the total energy consumption. Operation of Chiller plant is a major component of the high energy consumption of the whole air-conditioning system.
Improving the operating efficiency range of the chillers operation is a key energy saving opportunity.
As part of EHSMS, energy conservation from this project certainly contribute to reduction of air pollution in the local environment particularly fuel exhaust emission from thermal power plant.
Project Charter
Business Case:
DEFINE
DEFINE
Problem Statement:
Project Goal:
Improve and maintain Chiller plant operating efficiency not more than 0.75 kW/ton to realize energy saving without sacrificing the quality of air-conditioning services.
The central chiller plant serves the 24/7 cooling requirement of the building ranging from 200 to over 1,800 tons. Data shows that the plant has the capability to operate from 0.74 – 0.80 kW/ton efficiency range to deliver this cooling demand. However, it also operates inefficiently to an undesirably low value of 1.10 kW/ton. This clearly indicates that there are factors that affect the overall performance efficiency of the plant.
Automation System
Space heat load
Chiller Plant
ChwPCP
Chiller
CT
Illustration of Basic Chiller Plant Operation
Amount of heat in the space = Air-conditioning load which expressed in Tons
Efficiency = KW / TON
Chillers (5-units)ChwP – Chilled Water Pump (4-units) CP – Condenser Water Pump (5-units) CT – Cooling Tower (4-units)
StartChiller-5(350T)
6:30 amAdd 1-Chiller
(700T)
Add 1-Chiller(700T)
Add 1-Chiller(700T)
Load?
>/ = 1750
> 1750
= 1400
Subtract1-Chiller(350T)
MaintainOperatingChillers
Subtract1-Chiller(350T)
Subtract1-Chiller(700T)
Subtract1-Chiller(700T)
Subtract1-Chiller(350T)
Load?
= 1400
= 1400
= 700
Load?
Subtract1-Chiller(700T)
Subtract1-Chiller(700T)
Subtract1-Chiller(700T)
Subtract1-Chiller(700T)
= 700
= 700
= 350
MonitoredLoad= 350T
MonitoredLoad
>1050T
A
B
C
A
B
C
A
B
C
High Level Process Map
24/7
Operation
Automation System
3 x 700T
2 x 700 T1 x 350 T
2 x 700
Air-conditioning Load (Tons)
> 1750> 1400< or = 350 > 1050> 700> 350
1- 350T Chiller1- ChwP1- CP1-CT
1- 700T Chiller1- ChwP1- CP1- CT
1- 350T Chiller1- 700T Chiller1- ChwP2- CP2- CT
3- 700T Chiller3- ChwP3- CP3- CT
2- 700T Chiller2- ChwP2- CP2- CT
1- 350T Chiller2- 700T Chiller2- ChwP3- CP3- CT
Legend: ChwP – Chilled Water Pump (4-units) CP – Condenser Water Pump (5-units) CT – Cooling Tower (4-units)
High Level Process Map
C h i l l e r s O p e r a t i o n
Supplier Inputs Process Output Customer
ADB Air-conditioning load Load based Efficient chillers ADB
Chillers Chillers operation
Instrumentation Operation
Controls (automation)
Operators
Operation best practices
Power
Auxiliaries (Pumps/ Cooling Tower)
Weather
SIPOC DiagramS I P O C D i a g r a mS I P O C D i a g r a m
Ave. Eff. = 0.75 kw/ ton
0.70 kw/ Ton
Present:
Translation to Savings ( Illustration )
Improved by 7.5%:
Savings for every 100 Tons
100 tons x (0.75 – 0.70) Kw/ton x Php 7.00/Kw-hr = Php 35.00 per 100 ton/hr
Load, tons x (1.0 - .75) kW/ton x 8 hrs x Php 7 =
Measure
Data Collection and Consolidation:
Retrieve/ download 2005 data from Chillers Automation System (Trane Tracer Summit).
Average 24-hrs operation efficiency of central chiller plant.
Initially use 5-months (March – July 2005) as sample data to measure the process capability.
Measurement
Date Average Date Average Date Average Date Average Date Average
March Load, TonsEfficiency, KW/
Ton April Load, Tons
Efficiency, KW/ Ton
May Load, TonsEfficiency, KW/
Ton June Load, Tons
Efficiency, KW/ Ton
July Load, Tons
Efficiency, KW/ Ton
1 815.92 0.72 1 866.60 0.74 1 292.57 0.98 1 913.89 0.77 1 875.03 0.79
2 780.68 0.72 2 385.22 0.94 2 347.09 0.95 2 904.56 0.83 2 484.44 0.91
3 697.45 0.69 3 389.98 0.71 3 895.77 0.84 3 879.60 0.78 3 234.30 1.67
4 780.03 0.74 4 878.12 0.81 4 852.28 0.80 4 489.48 0.72 4 993.06 0.76
5 453.33 0.70 5 800.96 0.76 5 871.03 0.79 5 264.29 1.10 5 867.67 0.74
6 272.63 1.24 6 703.52 0.84 6 833.40 0.84 6 939.75 0.78 6 846.89 0.75
7 762.31 0.74 7 835.26 0.75 7 536.83 0.73 7 869.72 0.77 7 897.01 0.72
8 751.18 0.75 8 813.76 0.78 8 290.61 1.00 8 858.82 0.77 8 909.14 0.76
9 214.43 0.76 9 494.26 0.74 9 954.75 0.85 9 848.32 0.76 9 488.10 0.76
10 980.95 0.74 10 325.75 0.87 10 1021.01 0.82 10 828.06 0.76 10 278.41 1.10
11 788.81 0.75 11 835.34 0.81 11 1025.99 0.82 11 476.90 0.76 11 970.82 0.78
12 219.37 0.75 12 860.54 0.75 12 1021.47 0.75 12 308.52 0.98 12 983.82 0.78
13 331.11 0.86 13 850.10 0.76 13 970.18 0.77 13 342.27 0.93 13 839.80 0.80
14 840.14 0.73 14 868.40 0.73 14 507.31 0.76 14 885.29 0.83 14 865.81 0.79
15 917.96 0.76 15 842.43 0.75 15 329.92 1.11 15 874.04 0.83 15 869.41 0.81
16 957.42 0.74 16 513.49 0.71 16 911.18 0.84 16 890.46 0.82 16 479.68 0.78
17 790.23 0.74 17 300.08 0.70 17 921.05 0.84 17 864.39 0.85 17 253.11 1.11
18 881.19 0.74 18 834.65 0.81 18 876.25 0.86 18 512.92 0.75 18 1015.01 0.79
19 455.97 0.75 19 787.41 0.81 19 903.47 0.82 19 329.75 0.97 19 950.66 0.79
20 314.35 0.86 20 811.84 0.80 20 859.33 0.82 20 991.56 0.84 20 938.44 0.79
21 822.47 0.77 21 853.91 0.76 21 521.84 0.73 21 996.12 0.78 21 960.29 0.77
22 807.37 0.77 22 805.18 0.76 22 331.80 0.83 22 1005.52 0.78 22 895.15 0.86
23 792.41 0.75 23 414.29 0.83 23 897.89 0.84 23 1020.49 0.74 23 493.93 0.81
24 325.99 0.74 24 307.56 0.97 24 1005.43 0.77 24 950.37 0.78 24 240.18 1.21
25 258.02 0.76 25 855.32 0.86 25 964.70 0.75 25 375.40 0.91 25 837.65 0.87
26 385.41 0.79 26 1009.72 0.77 26 992.87 0.75 26 292.27 0.99 26 844.47 0.86
27 290.12 0.70 27 936.57 0.78 27 935.96 0.76 27 862.61 0.83 27 861.87 0.86
28 908.57 0.75 28 1018.89 0.75 28 544.54 0.75 28 825.87 0.86 28 875.96 0.85
29 889.68 0.75 29 969.83 0.77 29 350.12 0.89 29 830.59 0.83 29 852.41 0.81
30 935.42 0.76 30 484.80 0.73 30 846.29 0.84 30 868.90 0.75 30 494.17 0.83
31 990.63 0.74 31 966.58 0.78 31 242.20 1.19
Historical Data/Chiller Operation
1.651.501.351.201.050.900.75
Median
Mean
0.830.820.810.800.790.780.77
Anderson-Darling Normality Test
Variance 0.01445Skewness 3.4986Kurtosis 17.9891N 153
Minimum 0.69000
A-Squared
1st Quartile 0.75000Median 0.780003rd Quartile 0.84000Maximum 1.67000
95% Confidence Interval for Mean
0.79740
12.99
0.83580
95% Confidence Interval for Median
0.77000 0.79105
95% Confidence Interval for StDev
0.10807 0.13541
P-Value < 0.005
Mean 0.81660StDev 0.12019
95% Confidence I ntervals
Summary for Efficiency, KW/ Ton
For Normal Data: P-Value > 0.05 Mean = Median
For this Normality Test: P-Value < 0.005 Mean (0.81660) not equal to Median (0.78000)
Measure Is data NORMAL?Is data NORMAL?
Efficiency, KW/ Ton
Perc
ent
1.751.501.251.000.750.50
99.9
99
95
90
80706050403020
10
5
1
0.1
Mean
<0.005
0.8166StDev 0.1202N 153AD 12.986P-Value
Probability Plot of Efficiency, KW/ TonNormal
Measure Normality TestNormality Test
Therefore, data is non-normal
Data is not in the straight line pattern
1.61.41.21.00.90.80.70.60.50.4
USLProcess Data
Sample N 153Shape 4.99894Scale 0.87099
LSL *Target *USL 0.75Sample Mean 0.816601
Overall CapabilityPp *PPL *PPU -0.13Ppk -0.13
Observed PerformancePPM < LSL *PPM > USL 705882PPM Total 705882
Exp. Overall PerformancePPM < LSL *PPM > USL 622827PPM Total 622827
Process Capability of EfficiencyCalculations Based on Weibull Distribution Model
Zlt = Ppk x 3; -0.13 x 3 = 0.39Zst = Zlt + 1.5; -0.39 + 1.5 = 1.11 sigma
MeasureProcess CapabilityProcess Capability
Count
Perc
ent
Efficiency, KW/ Ton
Count 7 7 5 5 4 3 3 3 2 218 2 2 2 2 2 1 1 1 1 716Percent 1210 8 7 7 5 5 5 5
125 3 3 3 2 2 2 1 1 1
111 1 1 1 1 1 1 1 5
Cum %
10
1222 30 37 4449 54 59 6469
8
72 75 7880 82 84 8586 88 89
8
9092 93 93 9495 95100
8Oth
er0.94
0.93
0.89
0.69
1.11
1.10
0.98
0.97
0.91
0.87
0.71
0.85
0.80
0.70
0.72
0.82
0.73
0.81
0.79
0.86
0.84
0.83
0.77
0.78
0.74
0.76
0.75
160
140
120
100
80
60
40
20
0
100
80
60
40
20
0
Pareto Chart of Efficiency, KW/ Ton
Measure Pareto Diagram for Chiller Plant Efficiency
Pareto Diagram for Chiller Plant Efficiency
No
. o
f D
ays
Pe
rce
nt
KW/ Ton
Count 7 7 5 5 4 3 3 3 2 218 2 2 2 2 2 1 1 1 1 716
Percent 12 10 8 7 7 5 5 5 5
12
5 3 3 3 2 2 2 1 1 1
11
1 1 1 1 1 1 1 1 5
Cum %
10
12 22 30 37 44 49 54 59 64 69
8
72 75 78 80 82 84 85 86 88 89
8
90 92 93 93 94 95 95 100
8
Oth
er
0.9
4
0.9
3
0.8
9
0.6
9
1.1
1
1.1
0
0.9
8
0.9
7
0.9
1
0.8
7
0.7
1
0.8
5
0.8
0
0.7
0
0.7
2
0.8
2
0.7
3
0.8
1
0.7
9
0.8
6
0.8
4
0.8
3
0.7
7
0.7
8
0.7
4
0.7
6
0.7
5160
140
120
100
80
60
40
20
0
100
80
60
40
20
0
Average Daily Efficiency, KW/ Ton
Diagram shows that the plant operates at the region of 0.74 – 0.78kW/ton most of the days.
Measure
Estimated Losses from Five-months Operation
Efficiency More than 0.75kW/Ton
Cost = Load, Tons x (Eff. - 0.75)kW/Ton x 24 hrs x PhP 7/kWhr
Efficiency Load Cost
0.76 9,107.00 15,299.76
0.77 9,187.00 30,868.32
0.78 9,799.00 49,386.96
0.79 5,901.00 39,654.72
0.80 2,503.00 21,025.20
0.81 5,551.00 55,954.08
0.82 5,014.00 58,964.64
0.83 5,597.00 75,223.68
0.84 7,000.00 105,840.00
0.85 2,695.00 45,276.00
0.86 5,804.00 107,257.92
0.87 1,163.00 23,446.08
0.89 350.00 8,232.00
0.91 859.00 23,089.92
0.94 1,074.00 34,282.08
0.97 914.00 33,781.44
1.10 2,449.00 144,001.20
871,584.00
US$ 17,089.88
Wide
Variation ofChiller PlantEfficiency
BestPractices
Technology
Controls
Operation
Machines
Personnel
ADB-Staff
Proficiency
Serv iceProv iders
BallCleaningEqpt
Pumps
CoolingTowers
Chillers
Efficiency
Operating-Parameters
Chillers
FieldDev ices(FlowmeterTempSensorPressGuagePowerMetering)
Automation
Obselency
Machine'sAge
Reporting-Abnormality
TimelyAdj ustment(Valv es/Controls)
DataMonitoring/Analysis
Cause and Effect Diagram for Chiller Plant Operation
Cause and Effect Diagram for Chiller Plant OperationAnalyze
Load, Tons
Eff
icie
ncy
, kW
/To
n
317
300
294
290
287
284
283
282
280
279
277
276
274
273
272
271
270
269
268
267
265
264
262
261
260
259
258
257
256
255
254
253
252
250
249
247
245
243
242
241
240
239
238
237
236
235
234
233
232
231
230
228
227
226
225
223
222
221
219
218
217
215
214
213
212
211
210
208
205
203
201
195
194
191
183
179
119
0.98
0.94
0.90
0.86
0.82
0.78
0.74
0.70
0.66
0.62
Efficiency vs. Load at 350-Tons Range
AnalyzeVerify Efficiency Behavior at
Different Load Range
No
. o
f D
ays
Perc
ent
kW/Ton
Count 9 8 6 5 4 4 2 2 1 118 7
Percent 12 10 10 8 8 7 7 7
16
6 5 4 3 3 3 1 1 1 1
15
5
Cum % 12 22 32 40 48 55 61 68
12
74 79 83 86 89 92 93 94 95 95
12
100
11 10 10
Oth
er
0.8
3
0.6
5
0.8
8
0.7
1
0.8
4
0.6
9
0.8
2
0.8
1
0.7
2
0.7
8
0.7
5
0.7
3
0.7
0
0.8
0
0.7
4
0.7
7
0.7
9
0.7
6160
140
120
100
80
60
40
20
0
100
80
60
40
20
0
Pareto Chart of Efficiency, 350-Tons Range
Analyze
Analyze
Plant Load, Tons
Effi
cie
ncy
, kW
/To
n
1909
1876
1851
1833
1828
1826
1823
1816
1778
1773
1765
1754
1749
1746
1741
1719
1713
1702
1697
1696
1690
1688
1686
1683
1654
1653
1642
1641
1636
1634
1610
1609
1600
1599
1587
1580
1579
1578
1576
1569
1568
1566
1550
1538
1534
1533
1531
1529
1527
1520
1519
1515
1514
1511
1508
1507
1506
1505
1503
1495
1494
1492
1479
1473
1467
1465
1457
1427
1419
1417
1413
1412
1406
1401
1390
1363
1355
1348
1340
1334
0.98
0.94
0.90
0.86
0.82
0.78
0.74
0.70
0.66
0.62
Load vs. Efficiency at 1400 - 1900 Tons (7:00am - 4:45pm; Office Hrs. Operation
Analyze
No
. o
f D
ays
Perc
ent
kW/TonCount 3 3 2 2 2 5
Percent 32 21 1139
10 4 3 3 2 2 2 2 2 226
4Cum % 32 53 63 73 77 80 84 86
13
89 91 93 94 96 100
12 5 4 4 3Other0.880.870.780.860.840.720.910.890.900.770.740.750.76
140
120
100
80
60
40
20
0
100
80
60
40
20
0
Pareto Chart of Efficiency, 1400 - 1900 Tons (7:00am - 4:45pm; Office Hrs. Operation)
Plant Load, Tons
Effici
ency
, kW
/To
n
799
794
758
737
714
704
696
675
661
658
657
656
655
652
646
645
642
638
635
633
632
629
628
627
626
625
624
621
620
619
618
617
613
612
611
610
609
607
606
605
602
601
600
599
595
594
590
588
586
585
582
581
576
571
570
568
567
565
563
562
560
558
552
546
544
542
540
529
525
523
516
513
504
491
479
475
468
455
454
446
416
394
372
367
364
1.36
1.28
1.20
1.12
1.04
0.96
0.88
0.80
0.72
0.64
Load vs. Efficiency at 351 - 700 Tons Range
Analyze
No
. Of
Day
s
Pe
rce
nt
kW/Ton
Count 5 5 4 4 4 3 2 2 2 115 1 1 1 1 1 1 1 6
Percent 12
12
10 9 8 7 7 6 5 4 4 3
11
3 3 2 2 2 2 1 1 1 1
10
1 1 1 1 5
Cum % 12 22 31 39
9
46 53 59 64 68 72 75 78 81 84
9
85 87 89 90 90 91 92 93 94 94
7
95 100
6
Oth
er
1.1
4
1.1
2
0.9
6
0.9
4
0.9
2
0.8
3
0.8
2
0.6
5
1.1
9
1.1
7
0.7
8
0.7
9
1.2
6
0.7
7
0.7
6
0.8
0
0.6
7
0.7
5
0.6
9
0.7
3
0.7
1
0.7
0
0.6
8
0.7
4
0.7
2140
120
100
80
60
40
20
0
100
80
60
40
20
0
Pareto Chart of Efficiency, 351 - 700 Tons Range
Analyze
Plant Load, Tons
Effi
cie
ncy
, kW
/To
n
1307
1287
1235
1178
1171
1158
1154
1118
1112
1107
1089
1084
1082
1078
1076
1072
1071
1057
1056
1052
1047
1044
1036
1025
1021
1019
1015
1007
1006
1003
1002
1000999
998
994
990
986
983
981
980
979
967
966
965
964
963
962
955
954
953
952
949
947
945
944
943
940
935
933
928
924
923
922
920
919
917
905
904
900
896
895
894
888
878
876
872
869
854
843
841
839
831
828
826
824
821
812
807
796
795
783
780
778
776
767
728
727
726
696
1.07
1.01
0.95
0.89
0.83
0.77
0.71
0.65
Load vs. Efficiency at 701 - 1400 Tons Range
Analyze
No
. of
Day
s
Pe
rce
nt
kW/Ton
Count 5 5 4 4 4 3 3 3 3 312 3 2 2 2 1 1 1 1 1 59
Percent 10 8 8 7 6 5 5 4 4
9
4 3 3 3 3 3 3 3 3 3
8
2 2 2 1 1 1 1 1 4
Cum %
7
10 18 25 32 38 43 48 53 57 61
6
64 68 71 74 76 79 81 84 86 88
6
90 92 92 93 94 95 96100
5
Oth
er
0.9
5
0.9
2
0.8
5
0.7
0
0.6
9
0.9
3
0.8
7
0.7
5
0.9
7
0.9
1
0.9
0
0.7
8
0.7
6
0.7
2
0.8
4
0.7
7
0.7
1
0.8
9
0.8
6
0.7
4
0.8
8
0.7
9
0.7
3
0.8
2
0.8
1
0.8
0
0.8
3
120
100
80
60
40
20
0
100
80
60
40
20
0
Pareto Chart of Efficiency, 751 - 1400 Tons Range
Analyze
Day (MARCH 2005)
Load, Tons
31302928272625242322212019181716151413121110987654321
1000
900
800
700
600
500
400
300
200
Time Series Plot of Load, Tons
Day (MARCH 2005)
Efficiency, KW/ Ton
31302928272625242322212019181716151413121110987654321
1.10
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
Time Series Plot of Efficiency, KW/ Ton
Day (APRIL 2005)
Efficiency, KW/ Ton
302928272625242322212019181716151413121110987654321
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
Time Series Plot of Efficiency, KW/ Ton
Day (APRIL 2005)
Load, Tons
302928272625242322212019181716151413121110987654321
1100
1000
900
800
700
600
500
400
300
Time Series Plot of Load, Tons
Day (MAY 2005)
Load, Tons
31302928272625242322212019181716151413121110987654321
1100
1000
900
800
700
600
500
400
300
200
Time Series Plot of Load, Tons
Day (MAY 2005)
Efficiency, KW/ To
n
31302928272625242322212019181716151413121110987654321
1.10
1.00
0.95
0.90
0.85
0.80
0.75
0.70
Time Series Plot of Efficiency, KW/ Ton
Day (J une 2005)
Load, Tons
302928272625242322212019181716151413121110987654321
1100
1000
900
800
700
600
500
400
300
200
Time Series Plot of Load, Tons
Day (J une 2005)
Efficiency, KW/ Ton
302928272625242322212019181716151413121110987654321
1.10
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
Time Series Plot of Efficiency, KW/ Ton
Day (J uly 2005)
Load, Tons
31302928272625242322212019181716151413121110987654321
1100
1000
900
800
700
600
500
400
300
200
Time Series Plot of Load, Tons
Day (J uly 2005)
Efficiency, KW/ To
n
31302928272625242322212019181716151413121110987654321
1.8
1.6
1.4
1.2
1.0
0.9
0.8
0.7
0.6
Time Series Plot of Efficiency, KW/ Ton
Tons
HourMinute
6543210301500453015004530150045301500453015004530150045301500
350
300
250
200
150
Time Series Plot of LOAD - Chiller No. 5 (12MN - 6:30AM)
kW/Ton
HourMinute
6543210301500453015004530150045301500453015004530150045301500
0.80
0.75
0.70
0.65
0.60
0.55
0.50
Time Series Plot of Efficiency - Chiller No.5 (12MN - 6:30AM)
June 30, 2005
kW/Ton
HourMinute
20191817161514131211109876453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045
0.75
0.70
0.65
0.60
0.55
0.50
Time Series Plot of Efficiency - Chiller No.2
Tons
HourMinute
20191817161514131211109876453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045
700
650
600
550
500
450
400
Time Series Plot of LOAD - Chiller No.2
June 30, 2005
Tons
HourMinute
17161514131211109876004530150045301500453015004530150045301500453015004530150045301500453015004530150045
700
650
600
550
500
450
400
Time Series Plot of LOAD - Chiller No.3kW/Ton
HourMinute
17161514131211109876004530150045301500453015004530150045301500453015004530150045301500453015004530150045
0.85
0.80
0.75
0.70
0.65
0.60
0.55
0.50
Time Series Plot of Efficiency - Chiller No. 3
June 30, 2005
kW/Ton
HourMinute
20191817161514131211109876453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045
0.85
0.80
0.75
0.70
0.65
0.60
0.55
0.50
VariablekW/Ton_1kW/Ton_2
Time Series Plot of Chiller Nos. 2 and 3 - Efficiency Comparisson
Chiller no.3Chiller no.2
Chiller no.2
Tons
HourMinute
20191817161514131211109876453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045301500453015004530150045
700
650
600
550
500
450
400
VariableTons_1Tons_2
Time Series Plot of Chiller Nos. 2 and 3 - LOAD Comparisson
Chiller no.2
Chiller no.3
June 30, 2005
Chiller no.2
Chiller no.3
Plant Load, Tons
HourMinute
1615141312111098764530150045301500453015004530150045301500453015004530150045301500453015004530150045
1700
1600
1500
1400
1300
Time Series Plot of Chiller Plant Load, Combination of Chillers Nos. 2, 3 & 5 Operation
Plant Efficiency, kW/Ton
HourMinute
1615141312111098764530150045301500453015004530150045301500453015004530150045301500453015004530150045
0.84
0.82
0.80
0.78
0.76
0.74
0.72
0.70
Time Series Plot of Chiller Plant Efficiency, Combination of Chiller Nos. 2, 3 & 5 Operation
June 30, 2005
Index
Kw
4140393837363534333231302928272625242322212019181716151413121110987654321
400
375
350
325
300
275
250
VariableRM3-kWRM2-kW
Time Series Plot of kW - Chiller Nos. 2 and 3
June 30, 2005
Efficiency, kW/Ton
HourMinute
18171615141312111098301500453015004530150045301500453015004530150045301500453015004530150045301500453015
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0.9
VariableEff-SatEff-Sun
Time Series Plot of Eff on Sat & Sun - Chiller No.1
Load, Tons
HourMinute
18171615141312111098301500453015004530150045301500453015004530150045301500453015004530150045301500453015
900
800
700
600
500
400
300
200
VariableLoad-SatLoad-Sun
Time Series Plot of Load on Sat & Sun - Chiller No.1
June 25 & 26, 2005
Efficiency, kW/Ton
HourMinute
181716151413121110984530150045301500453015004530150045301500453015004530150045301500453015004530150045301500
0.90
0.85
0.80
0.75
0.70
0.65
VariableRM-4 kW/tonRM-4 kW/ton_1
Time Series Plot of Efficiency - Chiller No.4 (March 5 & 26 Sat. Operation)
Load, Tons
HourMinute
181716151413121110984530150045301500453015004530150045301500453015004530150045301500453015004530150045301500
900
800
700
600
500
400
VariableRM-4 load
RM-4 load_1
Time Series Plot of Load - Chiller No.4 (Mar 5 & 26 Sat Operation)
Mar 05
Mar 26
Mar 26
Mar 05
Analyze
CHILLERS PART LOAD PERFORMANCE
PERCENT CAPACITY EVAPORATOR CONDENSERKW KW/TON
LOAD TONS EXIT TEMP. ENT. TEMP. ENT. TEMP. EXIT TEMP
100 700 42.0 54.4 88.0 97.3 388 0.554
90 630 42.0 53.2 88.0 96.4 353 0.560
80 560 42.0 52.0 88.0 95.5 317 0.566
70 490 42.0 50.7 88.0 94.6 283 0.577
60 420 42.0 49.5 88.0 93.7 249 0.593
50 350 42.0 48.2 88.0 92.8 215 0.614
40 280 42.0 47.0 88.0 91.8 184 0.657
30 210 42.0 45.7 88.0 90.9 150 0.714
20 140 42.0 44.5 88.0 90.0 121 0.864
Mar 14, Monday Mar 15, Tuesday Mar 16, Wednesday Mar 17, Thursday Mar 18, Friday
Date/ TotalkW/ ton Date/ Total
kW/ton Date/ Total
kW/ ton Date/ Total
kW/ ton Date/ Total
kW/ton
Time Tons Time Tons Time Tons Time Tons Time Tons
3/18/05 7:00 PM 853.25 0.85
3/18/05 6:45 PM
1046.61 0.79
03/14/05 6:30 PM
826.59 0.81 3/18/05 6:30 PM
912.92 0.83
3/14/05 6:15 PM
876.22 0.8 3/18/05 6:15 PM
943.03 0.83
03/14/05 6:00 PM
956.06 0.77 3/15/05 6:00 PM
913.04 0.78
3/16/05 6:00 PM
903.39 0.76 3/17/05 6:00 PM
941.75 0.8 3/18/05 6:00 PM
1040.84 0.78
3/14/05 5:45 PM
943.11 0.78 3/15/05 5:45 PM
931.97 0.79
3/16/05 5:45 PM
914.07 0.79 3/17/05 5:45 PM
936.55 0.81 3/18/05 5:45 PM
1004.8 0.8
3/14/05 5:30 PM
971.48 0.77 3/15/05 5:30 PM
977 0.78
3/16/05 5:30 PM
942.56 0.78 3/17/05 5:30 PM
924.59 0.82 3/18/05 5:30 PM
999.77 0.81
03/14/05 5:15 PM
982.08 0.78 3/15/05 5:15 PM
950.66 0.81
3/16/05 5:15 PM
923.15 0.79 3/17/05 5:15 PM
925.29 0.82 3/18/05 5:15 PM
996.56 0.8
03'14/05 5:00 PM
864.11 0.86 3/15/05 5:00 PM
865.88 0.86
3/16/05 5:00 PM
801.28 0.88 3/17/05 5:00 PM
819.13 0.91 3/18/05 5:00 PM
915.62 0.84
3/15/05 4:45 PM
3/15/05 4:45 PM
1328 0.78
3/16/05 4:45 PM
1314.46 0.77 3/17/05 4:45 PM
1230.31 0.81 3/18/05 4:45 PM
1314.73 0.77
TOTAL6,419.
65 5.57 5,966.554.8
0 5,798.91 4.77 5,777.62 4.97 10,028.13 8.10
AVERAGE 917.09 0.80 994.430.8
0 966.49 0.80 962.94 0.83 1,002.81 0.81
After Office Hour Operation
.
( kW, TONS)
Chiller System
CHILLER PLANT LAY-OUT
TonskW
Chilled WaterPump (kW)
Condenser WaterPump (kW)
Cooling Tower ( kW )
PLANT OUTPUT
Efficiency
CONDENSER
EVAPORATOR
COMPRESSOR
Building Cooling Demand
LOADTons
Power
Chilled Water(Flow, Temp.)
Chiller AutomationSystem
qualification
common knowledge
training
load
approach temperature
chilled water flow
condenser water temp.
chilled water temp.
regular maintenance
condenser water flow
malfunctioning control devices
data monitoring and indepth analysis
guides on decision making
chillers vs. pumps, cooling tower requirements
operating chillers vs. demand load
reporting of abnormalities
PEOPLE
C
chillers combination
C
C
C
CC
C
C
N
C
C
C
C
PARAMETERS BEST PRACTICES
OPERATION
c.t. out
chiller out
difference
difference
N
N
C
C
attitudeN
field
bms
C
Chiller
Plant Eff. Variation
weatherN
timely correction/ adjustment of
timely start-up/ shut-downof chillersC
Analyze Cause and Effect Diagram for Chiller Plant Operation
Cause and Effect Diagram for Chiller Plant Operation
Technology
– can’t be controlled
C
ChillerAutomation
C
– can be controlled
N
C
C
ChillerObsolencyN
I. Covered in the previous reviews - Analyze Phase:
a. Chillers load vs. efficiency profile at different operating time frames:office hours operationafter office hours operationnight operationSaturday and Sunday operation
b. Chiller plant’s load and efficiency trends for (5) five months (March – July 2005) operation;
c. Verification of individual chiller performance.
d. Cause and effect diagram for chiller plant operation.
II. Last review - Analysis Phase:
a. Trending of chillers operating parameters to verify whether these arewithin or outside normal range.
Temperature, deg C
Hour
Minute
20191817161514131211109876543210
300030003000300030003000300030003000300030003000300030003000300030003000300030003000
0.9
0.8
0.7
0.6
0.5
0.4
VariableEvap App TempEvap App Temp_1
Time Series Plot of Evaporator Approach Temperature - Chiller Nos. 2 & 3
Temperature, deg C
HourMinute
20191817161514131211109876543210300030003000300030003000300030003000300030003000300030003000300030003000300030003000
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
VariableCond App Temp
Cond App Temp_1
Time Series Plot of Condenser Approach Temperature - Chillers Nos. 2 & 3
design: 0.8 deg C
design: 0.77 deg C
clean: 1.4 deg C
Chiller No. 2
Chiller No. 3
Chiller No. 2
Chiller No. 3
Refrigerant
Water
Scale
Tube
Fouled Tube Clean Tube
Approach Temp. = Water temp. – Ref. temp.
Illustration of Approach Temperature
Say:Refrigerant Temp = 6 deg CWater Temp. = 6.8 deg CApproach Temp. = 6.8 – 6 = 0.8 deg C
temp.
6.8 deg C
6 deg C
Temperature, deg C
HourMinute
20191817161514131211109876543210300030003000300030003000300030003000300030003000300030003000300030003000300030003000
14
13
12
11
10
9
8
7
6
Variable
CHWR Temp
CHWR Temp_1
CHWS Temp
CHWS Temp_1
Time Series Plot of Chilled Water Supply & Return Temp, Chiller Nos. 2 & 3
Temperature, deg C
Hour
Minute
20191817161514131211109876543210
300030003000300030003000300030003000300030003000300030003000300030003000300030003000
36
35
34
33
32
31
30
29
28
27
Variable
CondW Temp, OutCondW Temp, Out_1
CondW Temp, In
CondW Temp, In_1
Time Series Plot of Condenser Water Temperature In & Out - Chillers Nos. 2 & 3
Active setting: 6.5 deg C
design: 31.11 deg C
Chiller No. 2
Chiller No. 3
Flow, liter per minute
HourMinute
20191817161514131211109876543210300030003000300030003000300030003000300030003000300030003000300030003000300030003000
7500
7000
6500
6000
5500
5000
Variable
CHWF, lpmCHWF, lpm_1
Time Series Plot of Chilled Water Flow, Chiller Nos. 2 & 3
upper limit: 5400lpm
design: 5110lpm
lower limit: 4800lpm
chillers shut-down transition
Flow, liter per minute
HourMinute
16151413121110987654321030003000300030003000300030003000300030003000300030003000300030003000
3600
3500
3400
3300
3200
3100
3000
2900
2800
2700
Time Series Plot of Chilled Water Flow - Chiller No.5
Temperature, deg C
HourMinute
16151413121110987654321030003000300030003000300030003000300030003000300030003000300030003000
0.7
0.6
0.5
0.4
0.3
Variable
Evap App Temp_2Cond App Temp_2
Time Series Plot of Evaporator and Condenser Approach Temp. - Chiller No.5
Upper Limit
Lower Limit
Design at full operation
Evaporator Design App. Temp = 0.44 deg C
Condenser Design App. Temp. = 0.61 deg C
VSD Pump in operation
Temperature, deg C
HourMinute
16151413121110987654321030003000300030003000300030003000300030003000300030003000300030003000
14
13
12
11
10
9
8
7
6
VariableCHWS Temp_2
CHWR Temp_2
Time Series Plot of Chilled Water Supply & Return - Chiller No.5
Temperature, deg C
Hour
Minute
161514131211109876543210
30003000300030003000300030003000300030003000300030003000300030003000
35
34
33
32
31
30
29
28
27
26
VariableCondW Temp In_2
CondW Temp Out_2
Time Series Plot of Condenser Water Temperature, In & Out - Chiller No.5
Design Condenser Temp.:In = 31.11 deg COut = 36.29 deg C
Cond. In Temp. - design
ChW Active temp set pt. = 6.5 deg C
AnalyzeThe analyzes show that:
1. With the operation of chiller no.1, the chiller plant efficiency goes to undesirably low value of more than 1kW/Ton.
2. Chiller no.4 is not efficient to operate below 650-Tons load and this contributes in not achieving the target of 0.75kW/ton. However, it was found that although this chiller is rated 700-tons but it can efficiently handle the load up to 800-tons.
3. Chillers nos. 2 and 3 are identical machine but the latter is more energy efficient than the former.
4. Chiller no.2 is exhibiting relatively higher condenser approach than chiller no.3. This could be one factor that affects the performance of chiller no.2.
5. Higher percentage of over 0.75kW/Ton chiller plant efficiency is in the load range of 701 - 900 tons which normally occurs outside regular office hours. This air-conditioning load is shared by 2 x 700-tons chillers which are operating at their lower efficiency zone.
6. Interview with Chiller and BMS operators revealed that their awareness on the chillers and Tracer operations is not consistent.
Improve
Short-term: Improve Best Practices:
1. Maintain the following chillers combination during office hours: a. chillers no. 2 + no. 3 at cooling demand range of 700+ – 1400 Tons;
b. chillers no. 2 + no.3 + no. 5 at cooling demand range 1400+ – 1750 Tons c. either chiller no. 2 or 3 + no. 5 + no. 4 when cooling demand is in the
range 1,750+ - 1,900 Tons.
2. Run either chiller no.2 or no. 3 on Saturday instead of chiller 4 which is programmed to run every Saturday.
3. Run chiller no.4 when it can be loaded by 650 – 850 Tons.
4. Coincide the operational test run of chiller no. 1 during weekly Genset operation on Sunday. This is more practical because the standby Generator units can be used more efficiently and stored diesel can also be gradually replaced rather its quality degrade overtime. This can bring savings from wastage of diesel, and payment to Meralco on energy used. This is possible because the Gensets are already undergoing regular preventive maintenance.
5. Maintain chillers operating parameters within the design tolerable range.
Long Term:
1. Installation of additional new 2 x 400-tons chillers will further improve the chiller plant operation in terms of available capacity and efficiency: a. there will be back up units in the event of efficient chillers breakdown; b. it will provide flexibility in the chillers operation particularly when cooling
demand only requires 1-big chiller and 1-small chiller; c. this will prolong the life of the chillers because there are more units to operate alternately.
2. Replace the 18-year old Chillers no.1 and 4 with new units having an efficiency of not lower than 0.6kW/Ton.
Improve
6. Weekly generation of chiller plant performance data from automation system and conduct an in-depth data analysis to identify areas which can be further
improved.
7. Enhance awareness of chillers operators and BAS on the chillers operation best practices and design operating parameters.
Date
Average Chiller Plant Efficiency,
kW/Ton
Remarks
02-Sep Saturday 0.72 Chiller no.4 operates from 8:00am - 1:00pm at a load range of 650 - 850 Tons. Chiller no.2 operates from 1:00pm - 6:30pm
03-Sep Sunday 0.69 Chiller no.5 operates the whole day because cooling demand was within 350-Tons
04-Sep Monday 0.71
05-Sep Tuesday 0.70 Chiller nos. 2, 3 and 5 operates during office hours
06-Sep Wednesday 0.70
07-Sep Thursday 0.69 Chiller no.5 on nighttime
08-Sep Friday 0.71
09-Sep Saturday 0.92 Chiller #1 operates from 11:00am - 4:40pm
10-Sep Sunday 1.11 Chiller #1 operates (9:00am - 6:00pm) during Gensets operational test run.
11-Sep Monday 0.70 Chiller nos. 2, 3 and 5 operates during office hours
12-Sep Tuesday 0.69 Chiller no.5 on nighttime
Chiller Plant Performance: September 02 – 12, 2006
Improve
Date
Effici
ency
, kW
/Ton
302928272625242322212019181716151413121110987654321
1.00
0.800.750.700.650.60
0.40
0.20
0.00
Chart of Chiller Plant Efficiency: September 2006b
Date
Effici
ency
, kW
/Ton
302928272625242322212019181716151413121110987654321
0.80
0.75
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
Chart of Chiller Plant Efficiency - Setpember 2006a
Improve
Full Operation of Chiller PlantSeptember 2006
Data from Chiller no.1 operation not included
Data from Chiller no. 1 operation on 09, 10 & 17 included.
Date
EFFI
CIE
NCY, k
W/T
on
*
Fri-
30
Thu-
29
Wed
-28
Tue-
27
Mon
-26
Sun-
25
Sat-
24
Fri-
23
Thu-
22
Wed
-21
Tue-
20
Mon
-19
Sun-
18
Sat-
17
Fri-
16
Thu-
15
Wed
-14
Tue-
13
Mon
-12
Sun-
11
Sat-
10
Fri-
9
Thu-
8
Wed
-7
Tue-
6
Mon
-5
Sun-
4
Sat-
3
Fri-
2
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
CHILLER PLANT EFFICIENCY: September 2005
Date
EFFI
CIE
NCY, k
W/T
on
Sat
-30
Fri-
29
Thu
r-28
Wed
-27
Tue
-26
Mon
-25
Sun
-24
Sat
-23
Fri-
22
Thu
r-21
Wed
-20
Tue
-19
Mon
-18
Sun
-17
Sat
-16
Fri-
15
Thu
r-14
Wed
-13
Tue
-12
Mon
-11
Sun
-10
Sat
-09
Fri-
08
Thu
r-07
Wed
-06
Tue
-05
Mon
-04
Sun
-03
Sat
-02
Fri-
01
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
CHILLER PLANT EFFICIENCY: September 2006 (a) The Chiller plant operation data sampled in 2006 is compared directly against the 2005 recorded data for statistical comparison
(b) 2006 efficiency graph does not include operation of chiller no. 1 on 09, 16 & 17 September.
NOTE:
Improve
Comparison of Chiller Plant Performance:September 2005 vs. September 2006
Day
Coolin
g L
oad, T
ons
Sat-
30-*
*
Fri-
29-3
0
Thu-
28-2
9
Wed
-27-
28
Tue-
26-2
7
Mon
-25-
26
Sun-
24-2
5
Sat-
23-2
4
Fri-
22-2
3
Thu-
21-2
2
Wed
-20-
21
Tue-
19-2
0
Mon
-18-
19
Sun-
17-1
8
Sat-
16-1
7
Fri-
15-1
6
Thu-
14-1
5
Wed
-13-
14
Tue-
12-1
3
Mon
-11-
12
Sun-
10-1
1
Sat-
09-1
0
Fri-
08-0
9
Thu-
07-0
8
Wed
-06-
07
Tue-
05-0
5
Mon
-04-
05
Su-0
3-04
Sat-
02-0
3
Fri-
01-0
2
1200
1050
900
750
600
450
300
150
VariableLOAD-05_1
LOAD-06_1
Chiller Plant Performance: September 2005 vs. September 2006
20062005
Improve
0.720.680.640.60
Median
Mean
0.7000.6950.6900.685
Anderson-Darling Normality Test
Variance 0.00056Skewness -1.47194Kurtosis 4.71836N 30
Minimum 0.61000
A-Squared
1st Quartile 0.68000Median 0.690003rd Quartile 0.70250Maximum 0.74000
95% Confidence I nterval for Mean
0.68315
1.41
0.70085
95% Confidence I nterval for Median
0.69000 0.70000
95% Confidence I nterval for StDev
0.01887 0.03185
P-Value < 0.005
Mean 0.69200StDev 0.02369
95% Confidence I ntervals
Summary for EFFICIENCY- September 2006 Data
Improve
P-Value (<0.005) is not > 0.05: Nonnormal Data
Zlt = Ppk x 3; 1.22 x 3 = 3.66Zst = Zlt + 1.5; 3.66 + 1.5 = 5.16 sigma
Improve
0.740.720.700.680.660.640.620.60
USLProcess Data
Sample N 30Shape 35.9193Scale 0.702043
LSL *Target *USL 0.75Sample Mean 0.692
Overall CapabilityPp *PPL *PPU 1.22Ppk 1.22
Observed PerformancePPM < LSL *PPM > USL 0PPM Total 0
Exp. Overall PerformancePPM < LSL *PPM > USL 21.7686PPM Total 21.7686
Process Capability of EFFICIENCY: September 2006aCalculations Based on Weibull Distribution Model
Date
Energy Consumption kW-hr
Savings
2005 2006 % kW-hr US$
September 416,949.98 372,366.15 11.00 44,583.83 6,241.74
Chiller Plant Energy Consumption Comparison: September 2005 vs. September 2006
Improve
Savings projection using 2005 chiller plant energy consumption as a baseline:
Date
Energy ConsumptionkW-hr
Projected Savings (Oct. – Dec. 2006)
2005 2006 kW-hr $
October 386,337.92
11% reduction November 380,319.60
December 294,298.78
Total 1,060,956.30 944,251.11 116,705.19 16,338.73
3-mo. Ave. 353,652.10 314,750.37 38,901.73 5,446.24
Improve
Savings projection using 2006 chiller plant energy consumption as a baseline:
Date
Energy ConsumptionkW-hr
Projected Savings (Jan. – Aug. 2007)
2005 2006 2007 kW-hr $
January 336,475.90 315,918.69
11 - 5.47 = 5.5%
reduction
February 358,084.34 348,927.42
March 372,587.31 389,587.96
April 407,332.36 377,500.28
May 460,954.37 432,149.09
June 455,858.47 426,856.35
July 429,991.66 406,101.85
August 441,813.55 387,458.95
Total 3,263,097.97
3,084,500.60
2,914,853.07 169,647.53 23,750.65
8-mo. Ave. 407,887.25 385,562.57 364,356.63 21,205.94 2,968.83
% Reduction 5.47 NOTE: The 5.47% reduction is a result of ISO Enercon initiatives.
Summary of Projected Savings:
Energy kW-hr
Cost $
Oil Equivalent Lit.
September - December 2006 161,289.02 22,580.46 42,096.43
January - August 2007 169,647.53 23,750.65 44,278.01
Total = 330,936.55 46,331.12 86,374.44
Improve
(a) 1 kW-hr = Peso 7.00Conversion Rate = P50.00/$
(b) 1 kW-hr = 0.261 liter oil equivalentConversion factor reference: Phil. DOE , BP 73
NOTE:
Energy Converted/ Consumed
CO2 SO2 NOX
1 kW-hr electric energy generated by oil
1.9 lb 0.008 lb 0.003 lb
1.9 (330,936.55)
0.008 (330,936.55)
0.003 (330,936.55)
Reduction of air pollutants emission from energy savings
628,779.45 lb 2,647.50 lb 992.81 lb
Reference: Data from Green Light Program, Environmental Protection Agency, USA
Projected reduction of air pollutants emission:
Action Plan Reference Responsible Status
Service Provider
ADB Staff
1.Implementation of guidelines for the efficient chillers operation.
Table 1, Table 2 , Table 3 and Table 4(To be posted at Chiller Plant and BMS room)
Service provider supervisorBMS and Chillers Operators – (BCC)
Duty Senior Engineering Officer/ Assistant Engineers
Implemented - 02 September 2006
2. Ensure chillers plant operating parameters are within the allowable design range.
Table 5 Service provider supervisorBMS and Chillers Operator – (BCC)
Duty Senior Engineering Officer/ Assistant Engineers
Discussed in BCC’s Training - conducted by J. Mendez last June 2006
3. Updating of Tracer Summit program when necessary.
Proposal for improvement Trane Philippines George Villamor/ Joey Mendez
Updated based on improve phase - 04 October 2006
4. Conduct a weekly in-depth analysis of data from Tracer Summit for the following: i. to detect any deviation from target efficiency of 0.75kW/Ton; ii. to identify areas for continual improvement.
Tracer Summit data logging Service provider supervisors – (BCC)
Joey Mendez Implemented – 10 September 2006
5. Immediate reporting of abnormalities on chillers and auxiliary equipment, and Tracer operation to FM shift engineers so that appropriate action can be decided.
Chillers Operation Log-sheets and Tracer Summit Monitoring
Service provider supervisorBMS and Chillers Operator - BCC
Discussed in BCC’s Training - conducted by J. Mendez last June 2006
6. Calibration of ADB Engineers and service providers on the chiller plant operation.
i. Trainings on Chillers and Tracer Summit Operation;ii. This 6-sigma control measure to be circulated in O&M group.
Service Provider Management – (BCC)
Joey MendezFM Shift Engineers
Provided BCC with Training on Chiller and Tracer Operation – June 2006
7. Monthly review of maintenance of the following: i. Chillers and Tracer Summit ii. Cooling towers and pumps, and associated electrical system and instrumentation devices. Improve as necessary.
i.Maintenance technical field report (Trane Philippines)ii. Computerized Maintenance Management System (CMMS) report - (BCC)
George Villamor (for Tracer and instrumentation)Assistant Engineers (for mechanical and electrical system)
On-going
8. Ensure availability of spare parts and supplies for the continuous operation of chiller plant.
Critical items inventory in Oracle system
ADB Assistant Mechanical Engineers
covered in 1st wave 6-sigma project
Control Control Measure And Guidelines
Control Measure And Guidelines
Table 1: SUNDAY OPERATION
CHILLERS CONDITION OF OPERATION REMARKS
RM no. 1
Run during half-day Gensets operational test. This unit is in normally unavailable status at Tracer Summit;
Manually start-up/ shut-down the chiller through Tracer Summit. Proceed to local start up/ shut-down if Tracer is not working.
RM no. 5 Maintain in operation if No GENSETS operational test and if the load is within 350-Tons.
Or after Genset operation if the load is within 350-tons
Closely monitor the chiller load.
RM no. 3 No Genset Operation and if load is over 350-Tons
Or after the Genset operation if load is over 350-tons
Closely monitor chiller load.
Manually start the chiller through Tracer Summit. Proceed to local start up/ shut-down if Tracer is not working.
RM no. 2 If RM no. 3 is not available
Control
Table 2: MONDAY – FRIDAY (Regular Office Hours)
Chillers Condition of Operation Remarks
COOLING LOAD: 1100 – 1400 TONS
RM no. 2 + RM no.3 Priority Tracer Summit automatically controls these chillers operating combination.
RM no. 4 + RM no. 3 If RM no. 2 is not available
RM no. 2 + RM no. 4 If RM no. 3 is not available
COOLING LOAD: 1450 – 1800 TONS
RM no. 5 + RM no. 2 + RM no. 3 Priority Tracer Summit automatically controls these chillers operating combination.
RM no. 5 + RM no. 3 + RM no. 4 If RM no. 2 is not available
RM no. 5 + RM no. 2 + RM no. 4 If RM no. 3 is not available
COOLING LOAD: >1800 TONS
RM no. 2 + RM no. 3 + RM no. 4 At over 1,800 Tons Tracer Summit automatically controls this chiller operating combination.
Control
Table 3: Saturday and Holidays Operation
Chillers Condition of Operation REMARKS
RM no.5 Maintain in operation if the load is within 350-Tons capacity.
Tracer Summit automatically controls these chillers operating combination.
RM no. 3 If load within the range over 350-Ton but not more than 700- Tons
RM no. 2 If RM no. 3 is not available
RM no.4 If load exceeds 700-tons Manually start the chiller through Tracer Summit.
Control
Chillers Condition of Operation REMARKS
RM no.5 • Normal operation• Tracer Summit automatically controls this chiller operation.
RM no.1 • If Chiller no. 5 is not available
Table 4: Night Operation
Control
TABLE 5: CHILLER OPERATING PARAMETERS
Unit Chiller # 2 & 3 Chiller # 1 & 4 Chiller # 5
Design Duty Tons 700 700 350
Power consumed- Clean/Design KW 388 500 200
KW per Design Duty - Clean/Design Kw/Ton 0.554 0.714 0.571
Exit Evap Temp. Deg F/C 42 5.55 42 5.55 44 6.67
Evap Flow RateGpm/Lpm 1350 5110 1350 5110 840 3179
Entering Evap Temp. Deg F/C 54.4 12.47 54.4 12.47 54 12.22
Evap Press. Diff Ft/mm 25.98 7918.7 23.57 7185 15.89 4843
Evap Approach Temp. Deg F/C 1.44 0.8 5.02 2.78 0.8* 0.44*
Entering Cond Temp. Deg F/C 88 31.11 88 31.11 88 31.11
Cond Flow RateGpm/Lpm 2100 7948.5 2100 7948.5 1050 39.74
Exit Cond Temp. Deg F/C 97.32 36.29 97.71 36.5 97.33 36.29
Cond Press. Diff. Ft/mm 11.3 3456.4 10.47 3191 9.24 2816
Cond Approach Temp.- Clean/Design Deg F/C
0.3/1.4
.17 / 0.77
3.63 / 8.03
2.01 / 4.46
0.6 / 1.1
0.3 / 0.61
Motor RLA Amps 62 77 30
Voltage Volts 4160 4160 4160
Project benefits:
Financial - Hard savings = $50,000.00/year
Environment Sustainability – Pollution prevention through reduction in carbon and other pollutants emission.
Quality air-conditioning services to ADB HQ (customer) at a lower cost.
- END -
Lesson Learned:
1. Using Minitab in analyzing the data, we found the following:> chiller no. 4 operates efficiently at loads higher than its rated capacity;> chillers no.2 and 3 though they are identical in design duty but perform at
different efficiencies.
2. Consistent compliance to the chiller plant operation best practices can significantly contribute to optimum performance of the plant.
3. Strength and weaknesses of the chiller plant operation are clearly identify to put in effective operating measures.
4. Process is simplified for the service providers to carry out the operation.
5. Raw data becomes highly valuable when it is properly organized, analyzed and used correctly for effective continual improvement.
Time Line
Define
Measure
Analyze
Control
Improve
Jan-Feb 2006
Apr–May 2006
June-September 2006
October 2006
Feb-March 2006
D
A
I
C
M