value addition by energy reduction -...
TRANSCRIPT
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
The Kingdom’s Vision Toward Energy
So the Kingdom’s VISION statements has direct impact on the BUILDING SECTOR which is to
CONSERVE ENERGY
to
Protect our Natural Resources “Hydrocarbon”
The Kingdom’s Vision Toward Energy
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
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
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 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
Existing Condition - GENERAL
• 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
Existing Condition - GENERAL
• 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.
Existing Condition - GENERAL
• 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 - 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.
General Observation of The Existing Conditions
• 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.
General Observation of The Existing Conditions
• 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
General Observation of The Existing Conditions
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.
** - Calculated based on our design criteria with assumptions.
Evaluation of Capacities
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.
Evaluation of the Existing Equipment/ System for Building
Group 3 Buildings Admin , Admin Annex and Cafeteria
• 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.
Evaluation of the Existing Equipment/ System for Building
Group 3 Buildings Admin , Admin Annex and Cafeteria
• 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.
Evaluation of the Existing Equipment/ System for Building
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.
Evaluation of the Existing Equipment/ System for Building
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
Evaluation of the Existing Equipment/ System for Building
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.
Evaluation of the Existing Equipment/ System for Building
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
Evaluation of the Existing Equipment/ System for Building
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
Evaluation of the Existing Equipment/ System for Building
Group 3 & 4 Buildings COOLING CAPACITY EVALUATION - GROUP 3
NO. BUILDING NAME EXISTING CAPACITY AT
SITE * (TR - NOM)
ESTIMATED BLOCK LOAD CALCULATION
** (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.
** - Calculated based on our design criteria with assumptions.
Evaluation of Capacities
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.
** - Calculated based on our design criteria with assumptions.
Evaluation of Capacities
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.
Evaluation of the Existing Equipment/ System for Building
Group (5 to 12) SUBSTATIONS
COOLING CAPACITY EVALUATION - SUBSTATIONS
NO. BUILDING NAME EXISTING CAPACITY AT
SITE * (TR - NOM)
ESTIMATED BLOCK LOAD CALCULATION
** (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.
** - Calculated based on our design criteria with assumptions.
Evaluation of Capacities
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.
Evaluation of the Existing Equipment/ System for Building
Control Room & Peroxide Storage
COOLING CAPACITY EVALUATION
NO. BUILDING NAME EXISTING CAPACITY AT SITE * (TR - NOM)
ESTIMATED BLOCK LOAD CALCULATION
** (TR - NOM)
REMARKS
1 CONTROL ROOM 150 200
2 PEROXIDE STORAGE 15
* - Based on whatever information provided from O&M Team. Need further validation.
** - Calculated based on our design criteria with assumptions.
Evaluation of Capacities
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
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
-
-
Short Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
SHORT TERM RECOMMEDATION
ESTIMATED COST FOR SHORT TERM
RECOMMENDATIONS IN SAUDI RIYALS
4
FIRE STATION
Water flow thru the stand-by chiller shall be shut by the operator until a future control system will be implemented with motorized valves.
0.0 SR
5
LAB
Water flow thru the stand-by chiller shall be shut by the operator until a future control system will be implemented with motorized valves.
0.0 SR
6 MAINTENANCE BLDG NEW
- 0.0 SR
7
MAINTENANCE BLDG
OLD
Water flow thru the stand-by chiller shall be shut by the operator until a future control system will be implemented with motorized valves.
Currently the SKM Model – AHU unit is not in working condition. Repair the unit to make it operational
20,000
Short Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
SHORT TERM RECOMMEDATION
ESTIMATED COST FOR SHORT TERM
RECOMMENDATIONS IN SAUDI RIYALS
8
MAIN CONTROL
ROOM
Water flow thru the stand-by chiller shall be shut by the operator until a future control system will be implemented with motorized valves.
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.
Short Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
SHORT TERM RECOMMEDATION
ESTIMATED COST FOR SHORT TERM
RECOMMENDATIONS IN SAUDI RIYALS
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
Water flow thru the stand-by chiller shall be shut by the operator until a future control system will be implemented with motorized valves.
Repair / maintain the Standby chiller to make it operational
30,000
Short Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
SHORT TERM RECOMMEDATION
ESTIMATED COST FOR SHORT TERM
RECOMMENDATIONS IN SAUDI RIYALS
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 - -
Short Term Recommendations & Cost Estimation
S.NO
BUILDING
NAME
SHORT TERM RECOMMEDATION
ESTIMATED COST FOR SHORT TERM
RECOMMENDATIONS IN SAUDI RIYALS
24 TECHNICAL BLDG
- -
25 WAREHOUSE - -
TOTAL COST FOR SHORT TERM RECOMMENDATION =
1,085,000
Short Term Recommendations & Cost Estimation
Long Term Recommendations & Cost Estimation
UTILIZING THE EXISTING SYSTEM CONCEPT
Long Term Recommendations & Cost Estimation
S.NO
BUILDING
NAME
LONG TERM RECOMMEDATION
ESTIMATED COST FOR LONG TERM
RECOMMENDATIONS IN SAUDI RIYALS
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
Long Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
LONG TERM RECOMMEDATION
ESTIMATED COST FOR LONG TERM
RECOMMENDATIONS IN SAUDI RIYALS
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
Replace the Existing Units with the Calculated Nominal Capacity:
• PACU-1 = • AHU-1= • Chiller-1&2 = (300 TR including standby)
6 MAINTENANCE BLDG NEW
Replace the Existing Units with the Calculated Nominal Capacity:
• 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
Long Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
LONG TERM RECOMMEDATION
ESTIMATED COST FOR LONG TERM
RECOMMENDATIONS IN SAUDI RIYALS
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
Replace the Existing Units with the Calculated Nominal Capacity:
• 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
Replace the Existing Units with the Calculated Nominal Capacity:
• AHU-1= 25 TR • Chiller 1 & 2 = 25 TR each • AHU/ACCU-1& 2 = 50TR each • PACU = 25
Long Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
LONG TERM RECOMMEDATION
ESTIMATED COST FOR LONG TERM
RECOMMENDATIONS IN SAUDI RIYALS
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
Replace the Existing Units with the Calculated Nominal Capacity:
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
Long Term Recommendations & Cost Estimation
S.NO
BUILDING NAME
LONG TERM RECOMMEDATION
ESTIMATED COST FOR LONG TERM
RECOMMENDATIONS IN SAUDI RIYALS
17 SS0 Replace the Existing Units with the Calculated Nominal Capacity:
• PACU-1&2 = 40 TR Each
18 SS4
Replace the Existing Units with the Calculated Nominal Capacity:
• PACU-1&2 = 75 TR Each
19
SS5 Replace the Existing Units with the Calculated Nominal Capacity:
• AHU/ACCU-1&2 = 75 TR Each
20 SS6 Replace the Existing Units with the Calculated Nominal Capacity:
• PACU-1&2 = 30 TR Each
21 SS7 Replace the Existing Units with the Existing Nominal Capacity:
• AHU/ACCU-1&2=60TR Each
22 SS8 Replace the Existing Units with the Calculated Nominal Capacity:
• AHU/ACCU-1&2=70TR Each
TOTAL COST FOR LONG TERM RECOMMENDATION (OPTION-1)= 31,340,000
Long Term Recommendations & Cost Estimation
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
TOTAL COST FOR LONG TERM RECOMMENDATION (OPTION-2)= 32,000,000
Long Term Recommendations & Cost Estimation (Option 1)
Long Term Recommendations & Cost Estimation
OPTION 2
CENTRAL COOLING PLANT WITH WATER COOLED CHILLERS
SYSTEM FOR THE ENTIRE FACILITY
Long Term Recommendations & Cost Estimation (Option 2)
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
TOTAL COST FOR LONG TERM RECOMMENDATION (OPTION-2)= 50,000,000
Long Term Recommendations & Cost Estimation (Option 1)
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)
WATER COOLED CENTRAL PLANT
(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
Comparison of Water Cooled Central Plant vs Distributed Air Cooled Chiller Plants
AIRCOOLED DISTRIBUTED PLANT
(OPTION-1)
WATER COOLED CENTRAL PLANT
(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.
Comparison of Water Cooled Central Plant vs Distributed Air Cooled Chiller Plants
• 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
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
Identification of ECM
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
Identification of ECM
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