Value Addition by Energy Reduction -...

Value Addition by Energy Reduction PRESENTED BY:

Khalid AlMulhim

5 December 2017

What is the Kingdom of Saudi Arabia’s VISION

towards Reducing Energy Consumption ?

Introduction

Khalid A. Al Mulhim Engineering Consultant /

Business Development Director

at Protecooling | Suhaimi Design

Chair – ASHRAE MENA Region

• The Kingdom’s Vision Toward Energy

• Our Mission as Private Scoter

• Energy Auditing Services

• Overall Approach for Energy Projects

• Case Studies

Outline

• We will not dependent solely on OIL for our energy needs

• We will depend on new pillars by utilizing Renewable Energy such as

• Solar • Biomass • Wind Power

to meet our local energy consumption increase by generating 9.5 gig watts of renewable energy

• Increasing the competitiveness of our energy sector

The Kingdom’s Vision Toward Energy

• Providing subsidies with clear eligibility criteria to stimulate productivity and competitiveness among utility companies and open the door to investment and diversification of the energy mix in the Kingdom

• Protecting our vital national resources (hydrocarbon) by to reduce energy wastage

• Eliminate waste and continue to make spending more efficient

• Electricity will be better utilized by raise awareness and reward a culture of efficient spending


So the Kingdom’s VISION statements has direct impact on the BUILDING SECTOR which is to

CONSERVE ENERGY

to

Protect our Natural Resources “Hydrocarbon”


To be dedicated in playing a key and influential role in

“Energy Economy” by dramatically reducing energy

consumption and wastages, while improving energy

efficiency in operations within the buildings

The Kingdom’s Mission Toward Energy

We need to be ALIGNED in energy partnership with

companies and targeting reduction of energy wastage

beyond 50% by year 2030 to deliver Savings, Improving

Reliability, Performance & Comfort.

The Kingdom’s Mission Toward Energy

• To Implement Energy Conservation via Identification of

Efficient Measures

• To Provide Energy Auditing Services thru Qualified & Certified Energy Engineering Team Specialized in Various Disciplines

• To Adhere & Implement Energy Conservation Policy Using Local and International Standard / Procedures / Practices

• To Utilize Renewable Energy

“PROCESSIONALS” Mission in Building Sector

Sales

Industrial Commerial Resedinal

• Buildings are vital in the energy scenario of Saudi Arabia as they account for 50 - 60% of the total electricity consumption

• Due to harsh weather conditions is one of the most challenging areas in Saudi Arabia in terms of energy consumption.

Industrial; 23

Commercial; 26

Residential; 51

ENERGY CONSUMPTION IN SA

Trends Energy Consumption in Buildings

Sales

Industrial Commerial Resedinal

Breakdown of Domestic Energy Consumption

Buildings in Saudi Arabia consume around

TYPE OF LOAD MAJOR CITIES (Dam , RYD , JDH)

HVAC 55-73 %

Appliances 19-23 %

Lighting 7-11 %

Hot Water 0.5- 5 %

We can add Value to our building sector is by Energy Reduction

Added Value

Target All types of residential, commercial and institutional buildings sectors, o Hospitals, o Universities, o Shopping malls, o Municipalities, o Governmental buildings o Corporate houses

Energy Auditing Services should be thru Qualified and Certified Energy Engineering Team Specialized in Energy Audits:

• ASHRAE Energy Programs (www.ashrae.org) • Certified Energy Manager® (www.aeecenter.org) • Certified Lighting Efficiency Professional (http://www.aeecenter.org) • Building Energy Quotient (www.buildingenergyquotient.org) • Energy Efficient Buildings and Sustainable Construction

(http://www.tuv.com)

Energy Auditing Services

http://www.buildingenergyquotient.org/

Energy Auditing Certifications

A few learnings…

Examples from Sports…

Sergei Bubka - Ukranian pole vaulter

• Aim to cross 6-m mark

• Continuously improved

• Broke his own records > 14 times!

Efficiency Improvement - Continuous

2.6

2.4

2.2

2

1.8

1.6 1900 1920 1940 1960 1980

Scissors

Western Roll Straddle

Fosbury Flip

So rce: Pascale

2.6 2.4 2.2 2.0 1.8 1.6

1900 1920 1940 1960 1968 1980 1993

Olympic Gold Medal Winners in High Jump

2.45

1.7

2.24

Adopt the latest technology

Examples from Sports…

o Dick Fosbury

o Basically a Gymnast

o Applied principles of gymnastics to high jump

o Result – A quantum jump! - 2.24 m (1968)

o Javier Sotomayor (Cuba) is the current men's

record holder with a jump of 2.45 m (1993)

Inputs from Other Industries - Innovation

Energy Conservation at Macro Level

Measure of Energy Conservation Activities

Reduction in Specific Energy Consumption

Energy Conservation at Macro Level

Three-pronged Approach

Capacity Utilization

Fine-tuning

Technology Upgradation

Energy Audit Methodology

Ask questions like:

• What?

• When?

• Why?

• Where?

Macro Level - Methodology

Energy Input (A)

Theoretical Energy Requirement

(B) Work to Be

Done

Unavoidable Losses (C)

(D) Avoidable Losses

Losses

Losses

A = B + C + D

Focus should be

• To Concentrate on Avoidable Losses

• Quantify the Losses

• Identify Ways and Means for Reduction

• Implementation

Macro Level - Methodology

Overall Approach for Energy Projects

Identification / Prioritization Of ECMs

Engineering / Detailed Design of Approved ECMs

Construction Support / Implementation / Inspections

Delivery, Functional Performance Testing

Support & Inspection in Implementation

Monitoring & Verification & Help in Ongoing Commissioning / O&M

26

Detailed Energy Services

• HVAC System Performance Enhancements & Large Central Cooling

Plants and Piping System Network

• Special Studies with Motor / Pump / Fan / Air-compressor Systems and Network

• Power Quality Studies (Harmonic Analysis / Solution / Mitigation)

• Boiler / Steam Generation / Distribution Systems

• Lighting Systems

27

Detailed Energy Services

• Pre-project Energy Review Design and Recommendations

• Detailed Engineering & Implementation

• Project Commissioning and Performance Evaluations

• Assist Expansion Projects with Optimum Energy Consumption /

CAPEX • Energy Management Program / In-company Trainings

28

Energy Audit – EXISTING PROJECTS

Site Energy Audits and Retro Cx

• Brief Walk through Energy Audit:

• Quick Walk through Survey and Collect Data

• Identify Broad Areas for Study and Evaluation Approach

• Preliminary Energy Audit

• Identify Operational Improvements through Energy Study ( i.e. Secondary Pumps, Water Flows )

• Evaluate Potential Savings Possible in each Major Area (i.e. Control Sequence)

29

Energy Audit – EXISTING PROJECTS

Site Energy Audits and Retro Cx

• Detailed Energy Audit Existing Projects

• A Detailed Examination of Operations and Review Gaps / Variations in Design / Performance / Efficiency.

• Techno-economic Recommendations and Implementation Plan.

• Assistance to Implementation / Retro-commissioning

Review of Design for Energy Conservation

or Commissioning Process Cx

• Obtain Project Target Of KW / Unit

• Review Base Design Data

• Incorporate Efficient Vendor Equipment from Design Stage

• Assistance to Implementation and Retro-commissioning

• Sign Energy Partnership Agreement (EPA) and Identify Actions

Energy Audit – NEW GREEN FIELD PROJECTS

31

Energy Studies with Implementation

o Pumping Systems and Solutions

o Compressed Air Systems and Optimization

o Power Quality & Harmonic Analysis / Solution / Mitigation

o HVAC System, District Cooling Plants & Air / Water Balance

o Main Process Controls and Deploying Advanced Analytics

32

HVAC System

HVAC System is a Major Energy Consumer & any Performance / Energy Optimization Yields Benefits

• Evaluation of Existing System Configuration, Controls & Operation

• Evaluation of Performance of System in Terms of Energy, Process and Comfort.

• Recommendations for Improvement in Energy Conservation, Performance and Comfort.

• Support to Client Throughout Implementation including Commissioning Support and Delivery of Targeted Performance Indices (Kw/Tr).

33

Pumping System

• Evaluation of Pumping System Configuration and Performance

• Identification of Performance Deviation and Recommendations for Improvement.

• Identification of Pumping Control Issues and Implementation of Optimum Solutions

Pumping System Audits

34

Compressed System

Compressed Air System Audits

• Performance Evaluation of Air Compressor / Distribution Network

• Identification of Leakages and Cost Analysis

• Pre & Post Implementation Monitoring and Verification of Savings

35

Power Quality & Harmonic Analysis

• Data Collection thru Instruments

• Analysis of Data

• Identification of Problems and Mitigation

• Design of Mitigation Techniques

• Assistance / Implementation

Power Quality Has Become Very Important Not Limiting to Harmonic-mitigations, Audits Cover All Aspects Like, Transients, Flicker, Sags, Swells, Voltage Imbalance etc. with Engineering and Filter Solutions.

Chiller Plant Energy- ADVANCED ANALYTICS

• Optimize the Chiller Plant Operation Using Proven Patented Control System

• Suitable for New as Well as Retrofit Projects

Chiller Plant Energy Optimizer Using Online Energy Manager Patented Control System

Case Studies

Case Study 1- LOCAL UNIVERSITY

Scope: Conducted Energy Audits & Evaluate The Existing HVAC Equipment & Chilled Water System

Project Location: Eastern Provenance , Saudi Arabia • Evaluation of Remaining Operating Life of Equipment • Preparation of Phase-out Plan for HVAC System • Present Value Capital Replacement Cost • Evaluate Cooling Capacity & Hydraulic Delta-P Issues • Evaluate Chilled Water Delta-T and Controls Issues.

Buildings Covered Under Study Bldg No. Building Name

1 MAIN BUILDING 2 VISITOR CENTER

3 COMPREHENSIVE SERVICE CENTER

4 GYMNASIUM/VIP/MULTIPURPOSE HALL/WORKSHOP/WAREHOUSE 5 LIBRARY BUILDING 6 ITC & BUSINESS CENTER BUILDING 7 ELECTRICAL DEPARTMENT BUILDING

8 CIRCULAR DORMITORIES

9 CAFETERIA 10 MOSQUE

11 LIBRARY BUILDING

12 DIGITAL LIBRARY 13 AUDITORIUM 14 PRINTING BUILDING

15 ADMINISTRATION BUILDING 16 ACADEMIC BUILDING

Existing Condition - GENERAL

• Majority of the AHUs in existing buildings are about 30 years old and surpassed the working life.

• AHUs are single skin type with the damages in the BGT layer.

• HVAC controls are old and are not functioning properly.

• Chilled water piping system are old.

• Non availability of historic data for complaint log / Break down / maintenance.

• Existing chiller plant is not efficient. (Warm CHWS)

• Chilled water leakage issues in the existing CHW piping.

Damaged Coil & BGT layer


• Cooling coils damaged & corroded

• Existing control systems are nominally functional

• Some are in manual mode

• Existing “BMS” system not operational

• Existing chilled water piping configuration is not proper.

• Primary and secondary circuits not properly decoupled.

• Lack of clarity in operation by the operators.

• The existing control systems are old and nominally functional.

• All the AHUs are served by 3-way control valves.

Coils damaged and corroded at bottom of coil


• Shortage of cooling in the circular Dormitory Buildings and Cafeteria building

• ITC & Business Center Building, sometimes over cooling is reported.

• High CHWS from plant is a main contributor to cooling capacity problems

• Cooling problems are also due to improper zone control (Example: Circular Dormitory)

• Maintaining proper delta T is a key parameter for district cooling system operation.


• CHWS temperature is maintained by chiller plant and CHWR temperature depends on buildings HVAC system.

• Design CHWS is 5.5 Deg C and delta T is 8.9 Deg C.

• The buildings pumping system is operating with very high pressure drops. Primary pumps capacity is at 64 m (6.3 bar). The pressure drop of secondary pump is 50 m (5 bar).

Recommendations

• Replace Existing Control Valves & Connect to The Existing Controls to Improve the Performance of the Building Side to Provide Proper Delta-T. (Operation /Energy Measure)

• Replace All Old AHU’s with New Double-skin AHU’s. (Energy Measure)

• Replace the Entire HVAC System Control System. (Operation /Energy Measure)

• Further Evaluation of Air-side System including Zoning, Control Systems etc…….. Shall Also Be Considered.

Recommendations

(Mid-term Solution) • All Existing 3-way Valves Shall Be Replaced by 2-way Valves. (Energy

Conservation Measure)

• New Variable Volume Chilled Water Pumps Shall Be Installed At The Chiller Plant With Controls. (Energy Conservation Measure)

• Piping Arrangement Modified As A Standard Variable Volume Pumping System For The Primary. (operation / Energy Conservation Measure)

Priority List of Decommissioning

BUILDING NO BUILDING NAME PRIORITY

47 CAFETERIA BUILDING 1 46 DORMITORIES BUILDINGS 2 51 AUDITORIAM BUILDING 3 53 ADMINISTRATION BUILDING 4 52 PRINTING BUILDING 5 49 LIBRARY BUILDING 6 50 DIGITAL LIBRARY 7 48 MOSQUE 8 11 GYMNASSIUM AND MULTI PURPOSE HALL 9 54 ACADAMIC BUILDING 10

1 & 2 MAIN BUILDING AND VISITOR CENTER 11

Future Studies

• Air Side Temperature Control Issues.

• Energy Conservation Measures Such as Implementation of VAV Systems.

Future Steps for Consideration

Case Study 2

Case Study 2 - AC Plant / HVAC System

Scope: Studied AC Plant Performance and the

Associated HVAC System Project Location: Eastern Province, Saudi Arabia The study addressed the following: • Unit Condition and Performance • Capacity Study • Heat Load Calculation • Machine Obsolescence • HVAC System Analysis

General Observation of The Existing Conditions

• Majority of HVAC units are in service more than 20 years ( The effective operating life of Air cooled chillers is considered as 15 years)

• Most of the buildings are not provided with proper ventilation and the provision of the fresh air supply is closed. Therefore proper indoor Air Quality (IAQ) cannot be maintained inside the building as per Chapter-13 and ASHRAE Standard 62.1.

• Undercooling is reported in offices, corridors and Admin Annex etc. In some areas such as cafeteria additional DX units are provided to satisfy cooling requirement.


• The duty & standby Operation Of Chillers Is Not Properly Configured. This results in under cooling during peak load.

• Most of the Buildings, Chilled Water Piping and their accessories are Old And Obsolete.

• In Most of the buildings HVAC Controls are old and are not Functioning Properly and most of the operation is performed manually.


• Some of the Motorized Dampers are Not Operational in duty & standby operation. This will results in under supply of air to the space and also Impact in Cooling Performance.

• Many Chiller Units & Compressors Spares are Obsolete in the market due obsolete model from the manufacturer.

• Maintenance Staff main focus is to keep the equipment as much as possible in running condition.

• Many of the office and workstations have been Modified Due to Expansion of Plant Without Considering The HVAC System Impact. Above result Inadequate Distribution of Cooling and Temperature Controls


Recommendations (GENERAL)

• Replacement / Modification of Systems Due to The Following:

• Safeties and Other Code Requirements

• Under Capacities

• Improved Controllability

• Energy Performance

• Ageing of Equipment / Systems

Evaluation of The Existing Equipment / System for Building

Group 1 Buildings • AHU’s and ACCU’s are around 21 years Old • Under-cooling is reported in all areas served by the existing

units

• The AHU units, ACCU and Coils are Corroded and almost all the Dampers are Not Operational

• Some of AHU’s are Not Working for almost 3 years and these units are damaged

• Some of AHUs and Exhaust Fan are Not Working and the units are fully damaged

Group 1 Buildings • There are no Motorized Dampers in the AHUs for Duty

and Standby Operation

• Improper Exhaust System in the First Floor areas, where lot of fumes are present in the space

• In Chemical Storage areas and LABs, Adequate Ventilation and probably explosion proof equipment might be required in these areas as applicable.

Evaluation of The Existing Equipment / System for Building

Evaluation of Capacities

Group 1 Buildings COOLING CAPACITY EVALUATION

NO. BUILDING NAME EXISTING CAPACITY AT SITE

* (TR - NOM)

ESTIMATED BLOCK LOAD CALCULATION

** (TR - NOM)

REMARKS

1 PP1 200 500 Under-cooling

Reported 2 PP2 200 500 -

* - Based on whatever information provided from Operation Team. Need further validation.

** - Calculated based on our design criteria with assumptions.

Recommendations

Group 1 Buildings • Re-design and Re-establish the Capacities

of the HVAC Equipment

• Attention Shall Be Taken to Incorporate All the Ventilation Issues to Mitigate All Types of Risk in Compliance with Industrial Ventilation Standards.

• Replace All The Existing Equipment / System with New Units/ System Based on New Design.

Evaluation of the Existing Equipment/ System for Building

Group 2 Buildings • AHUs and ACCUs are around 17 Years Old

• Some of the Compressor in the ACCUs are Not Working

• As per O&M team, during summer some of the areas are hot

• In Peroxide Storage room there is No Exhaust is Provided, only Fresh Air is Relieved Through Relief Louver

Group 2 Buildings • Proper Control System need to be

Implemented to handle All Modes of Operation including smoke detection mode, gas detection mode (if applicable) etc. (Operation /Energy Measure)

• Requirement of Chemical Filtration shall be further studied during detailed engineering. (Safety Measure)

• It is recommended to combine the systems of Group 1 & Group 2 Buildings into a chilled water system to be more suitable for this type of application and to have more flexibility and energy efficient. (Operation /Energy Measure)

Recommendations

Group 2 Buildings

COOLING CAPACITY EVALUATION - GROUP 2

NO. BUILDING NAME EXISTING CAPACITY AT

SITE * (TR - NOM)

ESTIMATED BLOCK LOAD

CALCULATION ** (TR - NOM)

REMARKS

1 PPPH OFFICES 52 75 Under cooling reported

2 PPPH LINES 1 - 6 470 700 Under cooling reported

* -

Based on whatever information provided from O&M team. Need further validation.



Group 2 Buildings • The old units with operation around 20

years Shall be Schedule for Replacement (Operation /Energy Measure)

• Re-design and re-establish the capacities of the HVAC Equipment of total offices and Multipurpose. (Operation /Energy Measure)

• Attention shall be taken to incorporate all the ventilation issues to mitigate all types of risk in compliance with Industrial Ventilation standards (Safety Measure)

Recommendations (Option 1)

Group 2 Buildings • Re-design and re-establish the

capacities of the HVAC Equipment of total offices and Multipurpose Building. (Operation /Energy Measure)

• New Chilled water system with Variable Volume Pumping to serve the entire offices and Multipurpose Building. This system will result in efficient HVAC system. (Operation /Energy Measure)

Recommendations (Option 2)

Group 3 Buildings Admin , Admin Annex and Cafeteria

• Admin and Admin Annex Buildings are served by chilled water system.

• Cafeteria is served by AHU’s and ACCU’s. These units are around 16 years Old.

• The chillers serving Admin building are Very Old and the Standby Unit Is Not Functioning from last 3 years.

• Normally Motorized valve shall be provided in the chilled water system for multiple chillers duty and standby operation. In the Site Motorized Valves are Not Provided. This could affect the design supply temperature going to the building.



• The Condition of AHUs are Very Bad and the Chassis are Corroded.

• There is no Control Valves in most of the AHUs serving to Admin area.

• The Chiller serving to Admin Annex are 21 Years Old.



• Cafeteria Building is served by AHUs and ACCUs and the Units are 21 Years Old.

• During summer this AHUs Cannot Maintain the Desired Temperature, therefore additional floor stand split units are provided to maintain the design temperature.


Group 4 Buildings Technical Building, Maintenance Bldg. Old & New, MTBE Control Room Old and New, Lab PP, Offices, Warehouse Old and New, & Fire Station • Technical Building is served by Duty and Standby package units.

The Units are 21 Years Old and the cooling is satisfied.

• New Maintenance Bldg. is served by New 4 package units and are 10 years old. Balancing is Required in The Air Side and the cooling is satisfied.


Group 4 Buildings Technical Building, Maintenance Bldg. Old & New, MTBE Control Room Old and New, Lab PP, Offices, Warehouse Old and New, & Fire Station • Old Maintenance Bldg., is served by chilled water system and

AHU/ ACCU. The Chilled Water System is around 28 Years Old and there is No Motorized Control Valves.

• Duty and Standby AHU/ACCU is serving the Old Maintenance Bldg., served by the AHU/ACCU Unit are Continuously Under Maintenance and the cooling is satisfied


Group 4 Buildings Technical Building, Maintenance Bldg. Old & New, MTBE Control Room Old and New, Lab PP, Offices, Warehouse Old and New, & Fire Station • Control Room is served by Chilled water and are 8 years old

where as the AHU is 28 Years Old which is in Very Bad Condition, the Chassis is Corroded due to the Leakage Of Condensate Water and The Pumps are in Bad Condition and the cooling is satisfied.

• Control Room new is served by AHU and ACCU with energy recovery system and is 4 year old.


Group 4 Buildings Technical Building, Maintenance Bldg. Old & New, MTBE Control Room Old and New, Lab PP, Offices, Warehouse Old and New, & Fire Station • MTBE Lab is served partially via Chilled water system,

AHUs/ACCUs duty and standby and one Package unit. The Chilled Water System Is 26 Years Old. The chilled water AHU Is In Very Bad Condition, the chassis is corroded due to the leakage of condensate water and the pumps are in bad condition. As per the information from the O&M team the cooling is satisfied. The AHU/ACCUs are 17 years old.

• Warehouse old served by AHU/ACCU and package unit which are 5 year old. As per the information from the O&M team the cooling is satisfied


Group 4 Buildings Technical Building, Maintenance Bldg. Old & New, MTBE Control Room Old and New, Lab PP, Offices, Warehouse Old and New, & Fire Station • Fire Station is served by Chilled Water System With Duty and

Standby Chillers and are 28 Years Old. The chilled water AHU Unit is Corroded and in Bad Condition. As per the information from the O&M team the cooling is satisfied


Group 3 & 4 Buildings COOLING CAPACITY EVALUATION - GROUP 3


SITE * (TR - NOM)


** (TR - NOM)

REMARKS

1 ADMIN BLDG 180 150 Undercooling reported

2 ADMIN ANNEX 70 66 Undercooling reported

3 CAFETERIA & CLINIC 298

Undercooling reported, Additional Free standing units

used

* - Based on whatever information provided from O & M Team. Need further validation.



Group 3 & 4 Buildings

COOLING CAPACITY EVALUATION - GROUP 3 & 4

NO. BUILDING NAME EXISTING CAPACITY AT SITE * (TR - NOM)

ESTIMATED BLOCK LOAD CALCULATION **

(TR - NOM) REMARKS

1 TECHNICAL BUILDING 110 100 Existing capacity is OK. Ventilation not working

2 MAINTENANCE BUILDING (OLD) 85 150 No welding considered

Ventilation closed

3 MAINTENANCE BUILDING (NEW) 100 90 No welding considered

4 MTBE CONTROL ROOM 120 90 Ventilation not working

5 MTBE CONTROL ROOM (NEW) 40 60

6 LAB MTBE, PP &

OFFICES & NEW LAB

190 220 Considering half portion to be Lab

7 WAREHOUSE OLD 60 60 Ventilation closed

8 FIRE STATION 40

* - Based on whatever information provided from IZ team. Need further validation.



Group 3 Buildings • Re-design and re-establish the Capacities of the HVAC

Equipment for Admin , Admin Annex and Cafeteria/Clinic. (Operation /Energy Measure)

• Replace the Existing Chilled Water System with New Central Chilled Water System, along with Variable Primary Pumping System for Admin, Admin Annex and Cafeteria/clinic. This system will lead to energy conservation. (Operation /Energy Measure)

• The Option Of Redesigning the entire facility with VAV System in the Air Side to Improve the Indoor Temperature Control and Energy Conservation is recommended. (Operation /Energy Measure)

Recommendations

Group 3 & 4 Buildings • Replace all the existing individual Chiller Plant and other DX

Equipment (which are very old and practically the operational life of the equipment is exceeded) with a Centralized Large Chiller Plant to serve all the building (Group 3 & 4) with Variable Primary Pumping system. Total chiller plant capacity 1400 TR. (Operation /Energy Measure)

• Proper Ventilation System to be Implemented based on the Ventilation Standards. (Safety Measure)

• All the areas such as offices, labs and related areas which has possibility of Implementing VAV System shall be considered in the new design. (Operation /Energy Measure)

Recommendations

Group (5 to 12) SUBSTATIONS SAT 220, SAT-450MTBE, SS-0, SS-4, SS-5, SS-6, SS-7,SS-8 • These buildings are served by Duty and Standby A/C units. The

units are 21 Years Old and the cooling is satisfied.

• The Standby Units are Not Functional in SAT-220, SS-4, SS-5 & SS-6, In case of any failure in duty chiller will lead to sever problem in SAT220.

• The provision of the fresh air supply is closed. Therefore proper Indoor Air Quality (IAQ) Cannot Be Maintained Inside The Building as per the ASHRAE Standard 62.1.


Group (5 to 12) SUBSTATIONS

COOLING CAPACITY EVALUATION - SUBSTATIONS


SITE * (TR - NOM)


** (TR - NOM)

REMARKS

1 SAT 220 70 85 Ventilation Closed 2 SAT 450 MTBE 25 30 Ventilation Closed 3 SS-0 30 40 Ventilation Closed 4 SS-4 70 75 Ventilation Closed 5 SS-5 70 75 Ventilation Closed 6 SS-6 40 45 Ventilation Closed

7 SS-7 60 55 Ventilation Short-Circuit

8 SS-8 70 Ventilation Closed

* - Based on whatever information provided from O&M Team. Need further validation.



Group (5 to 12) SUBSTATIONS • The building shall be Re-designed With Proper Ventilation

System and accordingly units shall be schedule for replacement with new control system. (Safety Measure)

• Even though The Unit is 21 Years Old, Currently the unit is delivering the cooling (Without Proper Ventilation). However due to the age of the unit, it is recommended to schedule the replacement of these units. (Operation /Energy Measure)

Recommendations

Control Room • Chilled Water System is served for the office areas and are 21

Years Old.

• AHU- 6A and 6B are serving control room as duty and standby system, one Compressor for Each ACCU is Not Working.

• 2 AHUs duty and standby is serving Marshalling Area and are 5 years old. As per the information from the O&M team the cooling is satisfied

Peroxide Storage

• The DX unit system are 17 Years Old.

• Two DX units are serving Peroxide Storage room as duty and standby.


Control Room & Peroxide Storage

COOLING CAPACITY EVALUATION

NO. BUILDING NAME EXISTING CAPACITY AT SITE * (TR - NOM)


** (TR - NOM)

REMARKS

1 CONTROL ROOM 150 200

2 PEROXIDE STORAGE 15

* - Based on whatever information provided from O&M Team. Need further validation.



Control Room • As these Units are 21 Years Old, We recommend the entire

Control Building HVAC Units Shall Be Replaced with Central Chilled Water System with Variable Volume Pumping System for energy efficient operation. (Operation /Energy Measure)

Peroxide Storage

• A these Units are 17 Years Old, we recommend that PP2 Peroxide Storage Should Be Replaced with The Same System Based on New Design with Exhaust. (Safety Measure)

Recommendations

Short Term Recommendations & Cost Estimation


FIXING THE EXISTING SYSTEM

S.NO

BUILDING

NAME

SHORT TERM RECOMMEDATION

ESTIMATED COST FOR SHORT TERM

RECOMMENDATIONS IN SAUDI RIYALS

1

ADMIN

BUILDING

Water flow thru the chiller which is not in operating condition shall be shut-off.

0.0 SR

2

ADMIN ANNEX

Currently each chiller is delivering 50% cooling load. One compressor in each chiller is not working. Repair the chillers to deliver full Cooling load.

Install new Standby pump as only one pump is working presently.

Water flow thru the stand-by chiller shall be shut by the operator until a future control system will be implemented with motorized valves.

40,000/-

3

CAFETERIA &

CLINIC

-

-


S.NO

BUILDING NAME




4

FIRE STATION


0.0 SR

5

LAB


0.0 SR

6 MAINTENANCE BLDG NEW

- 0.0 SR

7

MAINTENANCE BLDG

OLD


Currently the SKM Model – AHU unit is not in working condition. Repair the unit to make it operational

20,000


S.NO

BUILDING NAME




8

MAIN CONTROL

ROOM


0.0 SR

9 MAIN CONTROL ROOM NEW

-

-

10 PP CONTROL ROOM & PP CONTROL

ROOM PP3 PROJECT

Two Trane ACCUs are delivering 50% cooling load. Perform repair / maintenance to make the ACCU units fully operational.

40,000

11

PP1

As per the site information, Currently all units are not delivering the desired cooling capacity. Provide new additional AHUs/ ACCUs after performing detailed engineering.

700,000 Estimation for around

200 TR capacity.


S.NO

BUILDING NAME




13 PEROXIDE STORAGE -. -

14 BLDG ANNEX Recommended to implement permanent solution as per the schedule of implementation.

-

15

OFFICES BLDG

Provide additional units to overcome the under cooling reported in the offices.

Make the standby unit -AHU-4B operational which is serving to control room

Make the Return fan Operational for AHU 3A.

150,000

16

SAT 220


Repair / maintain the Standby chiller to make it operational

30,000


S.NO

BUILDING NAME




17 SAT 450MTBE3 - -

18 SS0 - -

19

SS4

Repair / maintain or replace the standby Packaged unit to make it fully operational.

25,000

20 SS5 Repair / maintain or replace the Standby DX unit to make it operational

25,000

21 SS6 Repair / maintain or replace the Standby Package unit operational

25,000

22 SS7 - -

23 SS8 - -


S.NO

BUILDING

NAME




24 TECHNICAL BLDG

- -

25 WAREHOUSE - -

TOTAL COST FOR SHORT TERM RECOMMENDATION =

1,085,000


Long Term Recommendations & Cost Estimation

UTILIZING THE EXISTING SYSTEM CONCEPT


S.NO

BUILDING

NAME

LONG TERM RECOMMEDATION

ESTIMATED COST FOR LONG TERM


1

ADMIN

BUILDING

Replace the Existing Units(5-AHU) with the Existing Nominal Capacity

• 3-Chillers(2 Duty& 1Standby)= 90TR each • AHU-1, AHU-2, AHU-3, AHU-4, AHU-5

2

ADMIN ANNEX

Replace the Existing Units(2-AHU) with the Existing Nominal Capacity

• Chillers-1 & 2 = 70 TR • AHU-1= 25 TR ,AHU-2= 45 TR

3

CAFETERIA &

CLINIC

Replace the Existing Units(4-AHU/ACCU) with the

Calculated Nominal Capacity • AHU/ACCU-1= 150 TR • AHU/ACCU-2= 110 TR • AHU/ACCU-3= 20 TR serving to (Clinic) • AHU/ACCU-4= 25 TR


S.NO

BUILDING NAME




4

FIRE STATION

Replace the Existing Units with the Calculated Nominal Capacity:

• AHU-1 = 40 TR • Chiller -1&2 = 40 TR

5 PP CONTROL ROOM


• PACU-1 = • AHU-1= • Chiller-1&2 = (300 TR including standby)

6 MAINTENANCE BLDG NEW


• 1-AHU/ACCU= 90TR • 1-AHU=60 • 2 chillers(1 Duty & 1standby) = 60TR

7

MAINTENANCE BLDG

OLD

Replace the Existing Units(4-PACU) with the Existing Nominal Capacity

• PACU-3= 25 TR • PACU-4= 25 TR • PACU-5= 25 TR • PACU-6= 25 TR


S.NO

BUILDING NAME




8

MAIN CONTROL

ROOM

Replace the Existing Units with the Existing Nominal Capacity.

• 1-AHU= 120 TR • Chiller 1& 2= 120 TR Each

9 MAIN CONTROL ROOM NEW


• DX Unit = 60 TR

10 PP CONTROL ROOM & PP CONTROL

ROOM PP3 PROJECT

Two Trane ACCUs are delivering 50% cooling load. Perform repair / maintenance to make the ACCU units fully operational.

11

BLDG ANNEX , OFFICES BLDG


• AHU-1= 25 TR • Chiller 1 & 2 = 25 TR each • AHU/ACCU-1& 2 = 50TR each • PACU = 25


S.NO

BUILDING NAME




13 PEROXIDE STORAGE Replace the Existing Units with the Calculated Nominal Capacity:

• AHU/ACCU-1&2=15TR Each

14 WAREHOUSE Replace the Existing Units with the Calculated Nominal Capacity:

• PACU= 30 TR • DX UNIT = 30 TR

15

SAT 220


AHU-1 = 85 TR Chiller 1&2 = 85TR Each

16

SAT 450MTBE3 Replace the Existing Units with the Calculated

Nominal Capacity: • PACU-1&2 = 30 TR Each


S.NO

BUILDING NAME




17 SS0 Replace the Existing Units with the Calculated Nominal Capacity:

• PACU-1&2 = 40 TR Each

18 SS4



19

SS5 Replace the Existing Units with the Calculated Nominal Capacity:

• AHU/ACCU-1&2 = 75 TR Each



21 SS7 Replace the Existing Units with the Existing Nominal Capacity:




TOTAL COST FOR LONG TERM RECOMMENDATION (OPTION-1)= 31,340,000


Long Term Recommendations

& Cost Estimation

OPTION 1

DISTRIBUTED AIR COOLED CHILLED WATER SYSTEMS, PACKAGE UNITS & DX UNITS

Long Term Recommendations & Cost Estimation (Option 1)

GROUP BUILDING NAMES LONG TERM RECOMMENDATION

ESTIMATED COST FOR

LONG TERM RECOMMENDATIONS IN SAUDI RIYALS

1) ADMIN 2) ADMIN ANNEX, 3) CAFETERIA, 4) TECHNICAL BLDG, 5) MAINT. BLDG OLD & NEW, 6) MTBE CONTROL ROOM, 7) MTBE LAB, 8) WAREHOUSE OLD & NEW 9) FIRE STATION. 10) CONTROL ROOM 11) PP1 & PP2 12) PP2 PEROXIDE STORAGE 13) PPPH LINES 1 TO 6 14) PPPH OFFICES 15) SAT220, SAT450 16) SS0,SS4 TO SS8

REPLACE ALL EXISTING INDIVIDUAL CHILLER PLANT AND OTHER DX EQUIPMENT with NEW DISTRIBUTED AIR COOLED CHILLED WATER SYSTEMS, PACKAGE UNITS & DX UNITS

32,000,000




OPTION 2

CENTRAL COOLING PLANT WITH WATER COOLED CHILLERS

SYSTEM FOR THE ENTIRE FACILITY


GROUP BUILDING NAMES LONG TERM RECOMMENDATION

ESTIMATED COST FOR

LONG TERM RECOMMENDATIONS IN SAUDI RIYALS

1) ADMIN 2) ADMIN ANNEX, 3) CAFETERIA, 4) TECHNICAL BLDG, 5) MAINT. BLDG OLD & NEW, 6) MTBE CONTROL ROOM, 7) MTBE LAB, 8) WAREHOUSE OLD & NEW 9) FIRE STATION. 10) CONTROL ROOM 11) PP1 & PP2 12) PP2 PEROXIDE STORAGE 13) PPPH LINES 1 TO 6 14) PPPH OFFICES 15) SAT220, SAT450 16) SS0,SS4 TO SS8

Replace All Existing Individual Chiller Plant & Other DX Equipment with a Central Cooling Plant Utilizing Water Cooled Chillers.

50,000,000



Comparison of Water Cooled Central Plant vs Distributed Air Cooled Chiller Plants

AIR COOLED DISTRIBUTED PLANT

(OPTION-1)

WATER COOLED CENTRAL PLANT

(OPTION -2)

REMARKS

1. Initial Cost : SR. 31.3 million, • The total life cycle cost over

a period of 30 years will be SR 253.6 million (without considering financial cost factors)

1. Initial Cost SR. 50 million • The total life cycle cost over

a period of 30 years will be SR 211.2 million (without considering financial cost factors)

Even though the initial cost of OPTION-2 is higher, Cost savings in life cycle costing will be SR 42.5 million.

2. Operating life of Air-cooled chillers are around 15 years.

2. Operating life of Water

Cooled chillers will be around 25 to 30 years.

AIR COOLED DISTRIBUTED PLANT

(OPTION-1)


(OPTION -2) REMARKS

3. Annual Energy Consumption for the production of cooling (Air side not included) = 20.16 million KW-Hr.

3. Annual Energy Consumption for the production of cooling (Air side not included) = 11.2 million KW-Hr.

Annual Energy savings in option-2 only in cooling production = 8.96 million KW-Hr.

4. Annual Carbon Footprint for cooling plant = 15,120 ton CO2

4. Annual Carbon Footprint for cooling plant = 8,400 ton CO2

Annual reduction in Carbon footprint = 6,720 ton CO2


AIRCOOLED DISTRIBUTED PLANT

(OPTION-1)


(OPTION -2) REMARKS

5. Maintenance for cooling plant to be performed in DISTRIBUTED LOCATIONS.

5. Maintenance for cooling plant can be focused in ONE LOCATION.

Skill level of maintenance staff for plant is higher than Option-1.

Higher skill level is required for maintenance staff in option-2. However such staff can be mobilized.

6. NO WATER CONSUMPTION.

Heat rejection directly thru air cooled condensers.

6. Heat rejection thru cooling tower.

Annual Water consumption will be around = 115,000 Cu. M.

Treated Sewer Effluent Water can also be used in option-2.

TSE is already being proposed in various projects.


• It is recommendation is to implement the Central Water Cooled Chiller Plant for All the loads except some of the loads which are farther from the major loads such as some substations. (Operation /Energy Measure)

• The Central Chiller Plant could also be built as a packaged chiller plant, which are available from different manufacturers. (Operation Measure)

• The air side system for buildings where ever possible such as office buildings,

VAV system is recommended for improved temperature control and energy conservation. (Operation /Energy Measure)

• Chilled water system recommended is variable volume pumping system with 2-way control valves in the AHUs. (Operation /Energy Measure)

Recommendations

Implementation of Energy Audit & Cx is A Huge Potential for Energy Conservation Following cost benefits are reported in ASHRAE Journal – Feb 2011 Applying the Median Whole-building Energy-savings (Certainly Far Short Of Best Practices) to the U.S. Non-residential Building Stock Corresponds to an Annual Energy-savings Potential Of

$30 Billion By 2030. Greenhouse Gas Emissions Reductions of about 340 Megatons of CO2 Each Year.

Conclusion

Conclusion

“LETS NURTURE THE NATURE, SO THAT WE CAN HAVE

A BETTER FUTURE. ~ANONYMOUS ”

WWW.PROTECOOLING.NET [email protected]

Clientele

http://www.protecooling.net/

PROTEC ENERGY SERVICES

Review of Design for Energy Conservation

or Commissioning Process Cx

Energy Auditing / Retro Cx

Identification / Prioritization of ECMs

NEW PROJECT

EXISTINGPROJECT

Overall Approach for Energy Projects

107

Energy Performance Implementation Actions

(few measures being implemented during the study)

Low Hanging Fruits Ex: • Set-point Adjust

• Fine Tuning

• Reset / Review Control

• Sequence of Operations

• Trim Pump – Impeller

Identification of ECM

108


Energy Performance Implementation Actions (EPIAs), (having a payback of 1-2 years period)

Medium Term Measures Ex: • Sizing of Pumps

• Install New Controls

• Reschedule Operations

• Avoid Peak-loads

• Operate With VFD

• Reduce Electrical And Thermal System Losses

109


Long Term Measures Ex:

• Replace Inefficient Units with High Efficiency Equipment such as

• Units of Chillers

• Compressors,

• Pumps, Fans,

• Blowers

• Install Advanced Analytics with SCADA

Define Energy Performance Implementation Actions (EPIAs), (having a payback > 3 years)

110

Engineering and Detailing of Approved ECM’S

o Detailed Engineering Design / Drawings of Each Retrofit or New Equipment

o Vendor Interaction and Selection of Equipment

o Identify First Case / Best Practice Measure from Experiences (to Avoid Re-inventing the Wheel)

o Align with Site Specific Interventions with Water / Air / Fuel Systems

o Address Interface Requirements with Minimal CAPEX, by Utilizing Available Utility Resource / Equipment

111

o Support to Implementation by Supervision of Activities

o Prepare Pre-commissioning Formats/Stage-wise Checks

o Regular Follow-up & Update with Engg./Design Review

o Identify Plant Shutdown Requirements and Site Progress

o Support with Multi-disciplinary Teams (of Elec. / Mech. / Certified Energy Managers)

Construction Support & Inspection in Implementation of ECMs

112

Delivery, Functional Performance Testing

o Review Site Works and Define Look-ahead Schedule

o Comment on Vendor Supply, Spares and Design Adherence

o Review Test Plan, Logistics, Standards and Adequacy

o Support Functional Performance Testing Involving Vendors

o Review Operation/Control Philosophy and Client Readiness with Operations

113

Support & Inspection in Implementation of ECMs

o Implementation of ECM

o Support to Implementation by Supervision of Activities

o Prepare Pre-commissioning Formats / Stage-wise Checks

o Regular Follow-up & Update with Engg. / Design Review

o Identify Plant Shutdown Requirements and Site Progress

o Support with Multi-disciplinary Teams (Of Elec. / Mech. And Certified Energy Managers)

114

Monitoring, Verification (M & V) with O&M Support for ECMs

o Define M & V Steps with Available Metering Systems

o Support to Install Additional Field Meters/Analytics

o Review Targets and Develop New KPI via International Benchmarks

o Commissioning and Handover with Identified Energy Targets / Performances

o Review Test Records / O & M Manuals

Date post:	19-Apr-2018
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