industrial energy efficiency: fast, simple, proven, what's ... mr... · industrial energy...

Climate Solutions

Asia Pacific

24 May 2011

Industrial Energy Efficiency: Fast, Simple, Proven, what's holding us back?

Insert Footer ‹#›

The Journey Begins ………….


1983—Condenser water flow study

• 2 x 480 RT screw chillers + 2 x 120 RT reciprocating

• Design condenser flows 1,440 usgpm & 360 usgpm

• Magnetic flowmeter on main riser pipe

• 480 RT chiller flows ~ 1400usgpm

• 120 RT chiller flows ~ 1300 usgpm

• Same flowmeter on riser is reading both flows so accuracy not in question

• ―There are 3 kinds of people—those who make things happen, those who watch things happen, and those who don’t know what is going on‖


Engineering Education……

• Education is not the filling of a pail, but the lighting of a fire.

• William Butler Yeats

• “In Germany when an engineer says he has 25 years of

experience it means he spent one year making mistakes and

then 24 years repeating them” …………….Professor Kratel

• Education is the most powerful weapon which you can use to

change the world.

Nelson Mandela

Insert Footer ‹#› Chiller retrofit energy project - 1.53 years pay back = ROI > 50%

STM Factory, AMK

FREE PHASE : One chiller operation status

Analyse manufacturing curves vs

real time operating points

Real time operating point

Manufacturing curves

Deletion of triple valve of PMP21-202 during 8Mar2002-16Mar2002

Install new 20”

check valve with

low friction check-

valveand change the

pipe to 20 “

Deletion of 14”

TDV


CASE STUDY 1. ST Microelectronics Pte Ltd

Replacement of two Outside Air AHU

Year of completion: 2000

SUMMARY:

Savings of 140 kW

or 80% on

operating cost

AHU ENERGY RETROFIT


AHU ENERGY RETROFIT

CASE STUDY 1. ST Microelectronics Pte Ltd

Executive Summary OLD and NEW AHU PERFORMANCE

# AHU Parameter (100% fresh air): Unit OLD AHU NEW AHU

1 Total cooling capacity Ton refrigerant 340 354

2 Chilled water supply temperature Degree C 6

15-pre-cool,

6-final cooling

3 Chilled water temperature rise Degree C 5.5 11

4 Fan power consumption KW 35 7

5 Chiller power consumption KW 212 170

6 AHU efficiency KW/Ton 0.1 0.02

SAVINGS

# Savings (for 2 units): kW % $Sin/Year

1 Fan power consumption 56 80 72,800

2 Chiller power consumption 84 20 109,200

3 Total 140 182,000

Payback period of investments 1.9 years


―Good‖ ideas to save energy…..


Measured by SISIR and others……


Perpetual Motion Machine

1. Exhaust Fan Efficiency = 70%

2. Exhaust Fan Motor Efficiency = 85%

3. Windmill Fan Efficiency = 60%

4. Windmill Generator Efficiency= 80%

5. Total Efficiency = 0.7 x 0.85 x 0.6 x 0.8 = 29%

6. The Best Way to make a small fortune is start

with a BIG one


Turn Down the Energy/Tune Up the Profits

Only a third of U.S. manufacturers are seriously scrutinizing energy usage, where savings in five areas can move billions to the bottom line.

Philip Siekman

Labor is a big part of costs for chip packagers. In Muntinlupa City, just outside Manila, Pilipinas has over 6,000 employees. But given the need for huge clean rooms with oceans of filtered air, energy costs are high. Two years ago the

company called in a Singapore engineering firm, Supersymmetry Services,

and asked it how to reduce the electric bill in the 689,000-square-foot Muntinlupa plant as well as in a new facility planned not far away.

Supersymmetry was founded in 1988 by Lee Eng Lock, a Singapore-born

British-educated engineer with a growing international reputation for an iconoclastic approach to the design and construction of HVAC systems, particularly for electronics-plant clean rooms. Lee says there is "no special magic" needed to cut HVAC costs, just a "return to basic value-for-money thinking, careful measurement and analysis, openness to new ideas, and willingness to do hard work." He contends that the reasons companies settle for less efficient HVAC systems, at least in Asia, are "fear of loss of face, payola, very nice entertainment in Hawaii, karaoke lounges, golf, total disinterest, vested interest...." In Manila, Lee started with the easy ones: upgrading the lighting, turning off the office air conditioning at night, replacing screw-type air compressors with high-efficiency centrifugal units. Then he rebuilt or tuned up the air-conditioning and handling system. Ed Ornela, the company's corporate engineering director in the Philippines, calculates that the new air compressors cut the annual electric bill by $580,000; a new chiller and changes in chiller operation saved another $620,000; and other improvements lopped off $919,000. Amkor/Anan's electricity bill actually went up, from $7.2 million in 1995 to $8.5 million in 1997, as chip output doubled. But the power cost per chip, adjusted for chip size, tumbled by 37%. Examples like these ought to inspire companies that have paid little attention to their energy bills. A lot of waste, ironically, can be found in some U.S. semiconductor plants that feed work to companies like Amkor. A chip plant's electricity bill can easily hit $2 million a month. That concerns utilities and governments, particularly in the Pacific Northwest. The Northwest Power Planning Council, made up of representatives of four of the region's state governments, sponsored a workshop where Lee Eng Lock showed how to reduce HVAC power requirements in clean rooms from a current 1.2 kilowatts to two kilowatts per ton of cooling capacity to what he says is an achievable 0.6 kilowatt to 0.7 kilowatt per ton.


Power cost per chip produced, saved

37%.

In terms of $ - savings of more than

US$2 million annually Removal of secondary pumps

Installation of high efficiency chillers

Installation of magnetic flow meters and inverters


Energy savings of 90% of total electricity Air Handling Unit electricity use with additional 180 RT on top of original design tonnage. Production room specs met without fail! RM 350,000 per annum savings on RM 900,000 investment!

Inefficient Design is replaced by efficient and simple design with proper controls


Energy Project of the Year - International, 1996

Western Digital Factory

Using high efficient axial fan for re-circulation air.

Testing the roof with white reflective paint.

Unit cost comparison:


Total energy bill

Total energy used in G2+G3 plant

=Electrical + LPG

=USD 8 millions + USD 1.61 millions

=USD 9.61 million

Total electrical energy= 82,194,039 kWh

ENERGY USAGE

12 Recommendations to save US$5.4 million in utility cost.

Largest Solar Array in the world for Sanyo Wafer Fab

Sanyo Factory at Gifu


Energy Saving (kWh) per year (Steam energy gain) 43,800,000 kWh LPG savingڵ

Energy Saving (kWh) per year*(transmission loss 3%) 2,628,000 kWh Electrical savingڵ

Utility bill saving per year USD 5,220,000Per yearڵ

Investment USD25,000,000ڵ

Simple Payback 4.78 Yearsڵ

% Simple ROI 20.92ڵ

Recommendation 2 : Cogen Plant

• Energy Saving (kWh) per year 60,907,538 kWh (LPG fuel energy)

• Utility bill saving per year USD 1,540,636 per year

• Investment USD 5,000,000

• Simple Payback 3.24 Years

• Simple ROI 30.81 %

Recommendation 1 : Free Cooling and Free Heating


Energy Efficiency Project

for Sony Semiconductor

Capital Cost 4 Billion Yen

Energy Savings 25% of Bill

Payback within 3 Years


Optimising Fluid Movement

1. >250 Vacuum Pumps

• Presently using 13C Cooling

water, >150 kW pumps

• Constant water flow

• Specs is <30C inlet water, <40C

outlet water

• Convert to variable temperature,

variable flow

• Savings on chiller + Pumps >170 kW.


Insert subtitle here


Energy Audit/Workshop

for Shell Oil Refinery at Fredericia, Denmark


EDS Newcastle data centre—reverse clean room…March2008 --97% annual free-cooling


Low quality sensors lead to wrong results Site Seagate City

Subj Chiller Performances per Energy Audit data by Others

Description Ch 1 2 3 4 5 6 7

CHW Set Temp 5.5 5.5 5.5 - 5.5

CHWS T ( degC ) 5.8 5.8 6.3 6.1 5.8

CHWR T ( degC ) 11.2 10.8 11.1 10.9 11.3

dT 5.4 5.0 4.8 4.8 5.5

Design 30.5 30.5 30.5 30.5 30.5

CWS Temp ( degC ) 29.7 29.6 30.1 30.1 30.5

CWR Temp ( degC ) 33.8 34.2 34.6 33.8 35.3

dT 4.1 4.6 4.5 3.7 4.8

Design kW 730.0 730.0 730.0 730.0 730.0

% RLA Avg 87.0 90.3 98.0 91.7 93.7

A 85.0 89.0 95.0 89.0 88.0

B 90.0 93.0 100.0 94.0 100.0

C 86.0 89.0 99.0 92.0 93.0

Approach Temp Cond 1.0 0.9 0.9 0.0 0.4

Approach Temp Evap 1.5 2.3 2.0 2.1 1.3

IGV position % 100 100 97.1 100 86.9

Remark Limit by Vane stop Lim by I lim by I -

Flow CHW Lo 2960 2500 3150 3100 3700

Flow CHW Hi 3500 3000 3650 3350 3700

Design RTon 1,250 1,250 1,250 1,250 1,250

RTon Lo 1,199 938 1,134 1,116 1,526

RTon Hi 1,418 1,125 1,314 1,206 1,526

RTon Average measured 1,308 1,031 1,224 1,161 1,526

RTon Average at 100% 1,504 1,142 1,249 1,267 1,629

Design kW/Ton 0.58 0.58 0.58 0.58 0.58

Efficiency Lo 0.53 0.70 0.63 0.60 0.45

Efficiency Hi 0.45 0.59 0.54 0.55 0.45

Efficiency Avg 0.49 0.64 0.59 0.58 0.45

Note :

Per Others Data, all Chillers are peformance within design or better !!

Chiller efficiency too

good to be true !!

Filling in other trended data revealed questionable results

• xxxxxxxxxxxxxxxxxx

• xxxxxxxxxxxxxxxxxx


Typical overkill is educational…..

Cooling Tower

CWP CHWP

Chiller 300 RT

Transformer 1,000 KVA

Cooling Tower

Chiller 300 RT


Cooling Tower

Chiller 300 RT


Total Electrical: 3000KVA

Total Cooling: 900RT (Actual Use= 250RT)

Actual Use: 350KVA (Best Practice= 200KVA)

CWP CHWP CWP CHWP

Insert Footer ‹#› Chilled Water Ton

System kW (Before – 25th Nov to 19th Dec 2006)

System kW (After – 1st May 2007 to 14th May 2006)

Syste

m k

W

Savings in kW

Comparison of System kW (Before & After)


0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

0.5000

0.5100

0.5200

0.5300

0.5400

0.5500

0.5600

0.5700

0.5800

0.5900

0.6000

Ton-hr

kW-hr

kW/ton

Ton-hr 28,652 20,811 15,133 28,707 28,071 27,379 27,404

kW-hr 16,483 11,982 8,838 16,736 15,968 15,525 15,744

kW/ton 0.5753 0.5758 0.5840 0.5830 0.5688 0.5670 0.5745

Fri Sat Sun Mon Tue Wed Thu

15-Jun-07 16-Jun-07 17-Jun-07 18-Jun-07 19-Jun-07 20-Jun-07 21-Jun-07

Singapore Post Centre

System Efficiency (kW/Ton) – Daily/Weekly Analysis

0.5

75

3 k

W/T

on

0.5

75

8 k

W/T

on

0.5

83

0 k

W/T

on

0.5

84

0 k

W/T

on

0.5

68

8 k

W/T

on

0.5

74

5 k

W/T

on

0.5

67

0 k

W/T

on

Average

25,165

14,468

0.5755

For the week: 15-June-2007 to 21-June 2007


System kW/RT SingPost 18~20 Feb 2008


Galen Chiller Plant

Retrofit


Action on HFC Gases "Low Hanging Fruit" Opportunity to Combat Climate Change

• Nairobi, 22 June 2009 – A scientific paper, highlighting the need to accelerate action over a group of gases known as Hydrofluorocarbons (HFCs) as part of the climate change agenda, was today welcomed by the head of the UN Environment Programme (UNEP). The findings, by an international team of researchers are published in the Proceeedings of the National Academy of Sciences……. Under a scenario where carbon dioxide emissions are pegged to 450 parts per million HFCs could equal nine Gigatonnes - equivalent to around 45 per cent of total C02 emissions - by 2050 if their growth is unchecked.


JARN interview with USEPA’s Director Dr Stephen Anderson

“The cost of the refrigerant is a small part of owning an air conditioner or a refrigerator. The biggest part is the purchase price and the electricity. So, I think that the refrigerant costs are of minor significance.”

So far, there’s no essential use for HCFCs because the phase-out comes many years into the future. Most people believe there will be an essential use exemption for HCFC. And if that were true, and the HCFC-123 building air conditioners retained their competitive advantage for high energy efficiency, then they probably would get that exemption. So you could keep using 123 until a better refrigerant comes. But here’s the more important question, why would someone believe that HFC-134a will be in the market longer than HCFC-123?

There is no plan to further accelerate the HCFC phase-out, but there is every intention to accelerate the HFC-134a phase down. So HFC-134a may be gone from chillers before HCFC-123. Today when you go to buy, and you ask the question, which refrigerant will last the longest in the market, I don’t think it’s HFC-134a. HFC-1234yf should work anywhere HFC-134a is working today. Both HCFC-123 and HFC-134a are in regulatory jeopardy, but the difference is that HCFC-123 gets higher energy efficiency. For large chillers, it’s the top-runner.

HCFC-123 is currently the best in the market. With 134a under phase-out worldwide for cars, stationary is next. It’s exciting!

Nov2008


Ansari X prize --- Space Flight


IDEAS SOUGHT FOR BETTER DESALINATION – Aug 2007 Business Times, Singapore

• The Environment and Water Resources Ministry is looking for better ways to make clean water out of seawater.

• Its Environment and Water Industry Development Council is asking all local and overseas institutes of higher learning, research institutes and private sector companies to submit proposals for technologies which can desalinate seawater using a total energy consumption of not more than 1.5 kWh per m3 of water produced - less than half the energy now used by other technologies.

• The closing date is Nov 2. For more information. go to www.mewr.gov.sg/ewi .

http://www.mewr.gov.sg/ewi


…...Siemens Water Technologies team yesterday bagged a S$4 million grant from the Environment and Water Industry Development Council (EWI)…. used electricity instead of high pressure or heat to remove salt from sea water, and produced a cubic metre of pure drinking water on 1.5 kilowatt-hours (kWh) of power.

.

….PUB technology director Harry Seah described the novel approach as one which 'blows convention away'.

….Prof Lui …. 'This is what we call disruptive technology - and it's exactly what we're looking for.'

News of this new technology is a prelude to the cutting-edge technologies that will be on show at the Singapore International Water Week, which officially opens today.

.

Cheaper way found to make sea water drinkable—Straits Times, 24June2008


Negawatt - X Prizes

• First High Temp Chiller Plant to achieve 0.40 kW/RT

• First Low Temp Chiller Plant to achieve 0.50 kW/RT

• First low cost M&V hardware/software product for

chiller plant to achieve ARI-550 accuracy or better

• First Lighting System to achieve 200 Lumens/Watt

• First HVAC system to achieve 0.65 kW/RT

• First property developer to allow real time access to

various properties types for MEP systems, online

documentation, etc setting high standards


Latest NEA guidelines for energy audits in Singapore—June 2009

– Chilled water plant system performance

• System performance measurement error shall not exceed ±5%.

This implies the use of high accuracy thermometry and

calorimetry.

• Detailed method statement explaining how the required degree

of accuracy was achieved with the instruments and data

acquisition hardware employed.

• Data required to establish system performance must be

sampled and acquired simultaneously and continuously for a

minimum of 1 week at one-minute intervals.


Latest NEA guidelines for energy audits in Singapore—June 2009

• The appendices should include:

• Schematics and layout drawings of facility or building audited

• Details of instrumentation used – parameters monitored and

duration of monitoring for each parameter

• Data plots of performance of systems or equipment audited

• Energy efficiency of major equipment compared against

industrial benchmarks

• Measurement and verification (M&V) plan for monitoring and

verifying energy savings for each of the recommendations

• CD-ROM containing the raw measurement data


Performance metric : 9.69 secs/100 meters


Thomas Hartman, P E

The Hartman Company

June 2007,

automatedbuildings.com

Right now there is no off-the-shelf delivery

process in place to develop truly effective energy

efficiency improvements with long term

performance assurance.

Making Energy Efficiency Accountable


Ashrae--Chiller Plant Efficiency

0.5

(7.0)

0.6

(5.9)

0.7

(5.0)

0.8

(4.4)

0.9

(3.9)

1.0

(3.5)

1.1

(3.2)

1.2

(2.9)

NEEDS IMPROVEMENTFAIRGOODEXCELLENT

AVERAGE ANNUAL CHILLER PLANT EFFICIENCY IN KW/TON (C.O.P.)(Input energy includes chillers, condenser pumps, tower fans and chilled water pumping)

New Technology

All-Variable Speed

Chiller Plants

High-efficiency

Optimized

Chiller Plants

Conventional

Code Based

Chiller Plants

Older Chiller

Plants

Chiller Plants with

Correctable Design or

Operational Problems

Based on electrically driven centrifugal chiller plants in comfort conditioning applications with

42F (5.6C) nominal chilled water supply temperature and open cooling towers sized for 85F

(29.4C) maximum entering condenser water temperature and 20% excess capacity.

Local Climate adjustment for North American climates is +/- 0.05 kW/ton

kW/ton

C.O.P.


Simple Guide to retrofit success

• Ask for 1 minute trend data for chiller plant parameter

eg tons, kw/ton, flow rates, kw, pressures,

temperatures, ambient temp and wet bulbs for 3

months in spreadsheet format

• Ask for previous performance contract examples with

bank guarantees

• Ask for online internet access to previous projects

• Ask for ARI-550 accuracy of +-5% for chiller plant

efficiency, using as guides ASHRAE 14P & 22.

• Ask for 0.60 kW/RT or better for chiller plant


The Evolution of truth…

• All truth passes through three stages.

• First, it is ridiculed.

• Second, it is violently opposed.

• Third, it is accepted as being self-evident.

–

– Arthur Schopenhauer

German philosopher (1788 - 1860)

industrial energy efficiency: fast, simple, proven, what's ... mr... · industrial energy...

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