Title: Optimization of Central Air-conditioning Chillers System

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





Load?

= 1400

= 1400

= 700

Load?





= 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



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


Day (APRIL 2005)

Load, Tons

302928272625242322212019181716151413121110987654321

1100

1000

900

800

700

600

500

400

300


Day (MAY 2005)

Load, Tons

31302928272625242322212019181716151413121110987654321

1100

1000

900

800

700

600

500

400

300

200


Day (MAY 2005)

Efficiency, KW/ To

n

31302928272625242322212019181716151413121110987654321

1.10

1.00

0.95

0.90

0.85

0.80

0.75

0.70


Day (J une 2005)

Load, Tons

302928272625242322212019181716151413121110987654321

1100

1000

900

800

700

600

500

400

300

200


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


Day (J uly 2005)

Load, Tons

31302928272625242322212019181716151413121110987654321

1100

1000

900

800

700

600

500

400

300

200


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


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

Title: Optimization of Central Air-conditioning Chillers System

Documents