Fast, Simple, Proven, what`s holding us back

Transcription

Industrial Energy Efficiency:
Fast, Simple, Proven, what's holding us
back?
Climate Solutions
Asia Pacific
24 May 2011
The Journey Begins ………….
‹#› Insert Footer
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
STM Factory, AMK
Chiller retrofit energy project - 1.53 years pay back = ROI > 50%
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 8Mar200216Mar2002
Install new 20”
check valve with
low friction checkvalveand change the
pipe to 20 “
Deletion of 14”
TDV
AHU ENERGY RETROFIT
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
CASE STUDY 1. ST Microelectronics Pte Ltd
Executive Summary
OLD and NEW AHU PERFORMANCE
# AHU Parameter (100% fresh air):
Unit
OLD AHU
NEW AHU
Ton refrigerant
340
2 Chilled water supply temperature
Degree C
3 Chilled water temperature rise
Degree C
6
5.5
35
212
0.1
354
15-pre-cool,
6-final cooling
11
7
170
0.02
1 Total cooling capacity
4 Fan power consumption
KW
5 Chiller power consumption
KW
6 AHU efficiency
KW/Ton
SAVINGS
kW
1 Fan power consumption
56
2 Chiller power consumption
84
3 Total
140
‹#›Payback
Insert Footer
period of investments 1.9 years
# Savings (for 2 units):
%
80
20
$Sin/Year
72,800
109,200
182,000
―Good‖ ideas to save energy…..
Measured by SISIR and others……
Perpetual Motion Machine
1.
2.
3.
4.
5.
6.
Exhaust Fan Efficiency = 70%
Exhaust Fan Motor Efficiency = 85%
Windmill Fan Efficiency = 60%
Windmill Generator Efficiency= 80%
Total Efficiency = 0.7 x 0.85 x 0.6 x 0.8 = 29%
The Best Way to make a small fortune is start
with a BIG one
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...."
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
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 highefficiency 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
Inefficient Design is
replaced by efficient and
simple design with proper
controls
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!
Western Digital Factory
Using high efficient axial
fan for re-circulation air.
Energy Project of the Year - International, 1996
Unit cost comparison:
Testing the roof with
white reflective paint.
Sanyo Factory at Gifu
ENERGY USAGE
Total electrical energy= 82,194,039 kWh
Total energy bill
Largest Solar Array in the world for Sanyo Wafer Fab
Total energy used in G2+G3 plant
=Electrical + LPG
=USD 8 millions + USD 1.61 millions
=USD 9.61 million
12 Recommendations to save US$5.4 million in utility cost.
Recommendation 1 : Free Cooling and Free Heating
•
•
•
•
•
Energy Saving (kWh) per year
Utility bill saving per year
Investment
USD 5,000,000
Simple Payback
3.24
Simple ROI
30.81
60,907,538
kWh (LPG fuel energy)
USD 1,540,636 per year
Years
%
Recommendation 2 : Cogen Plant
‫ڵ‬Energy Saving (kWh) per year (Steam energy gain)
43,800,000 kWh LPG saving
‫ڵ‬Energy Saving (kWh) per year*(transmission loss 3%)
2,628,000
‫ڵ‬Utility bill saving per year
USD 5,220,000Per year
‫ڵ‬Investment
USD25,000,000
‫ڵ‬Simple Payback
4.78
Years
‫ڵ‬Simple ROI
20.92
%
kWh Electrical saving
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 13C Cooling
water, >150 kW pumps
•
Constant water flow
•
Specs is <30C inlet water, <40C
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
• xxxxxxxxxxxxxxxxxx
Seagate City
• xxxxxxxxxxxxxxxxxx
Chiller Performances per Energy Audit data by Others
Subj
Description
CHW Set Temp
CHWS T ( degC )
CHWR T ( degC )
dT
Design
CWS Temp ( degC )
CWR Temp ( degC )
dT
Design kW
% RLA Avg
A
B
C
Approach Temp Cond
Approach Temp Evap
IGV position %
Remark
Ch 1
5.5
5.8
11.2
5.4
2
5.5
5.8
10.8
5.0
3
5.5
6.3
11.1
4.8
30.5
29.7
33.8
4.1
30.5
29.6
34.2
4.6
730.0
87.0
85.0
90.0
86.0
1.0
1.5
6.1
10.9
4.8
7
5.5
5.8
11.3
5.5
30.5
30.1
34.6
4.5
30.5
30.1
33.8
3.7
30.5
30.5
35.3
4.8
730.0
90.3
89.0
93.0
89.0
730.0
98.0
95.0
100.0
99.0
730.0
91.7
89.0
94.0
92.0
730.0
93.7
88.0
100.0
93.0
0.9
2.3
0.9
2.0
0.0
2.1
0.4
1.3
100
100
97.1
Limit by Vane stop
Lim by I
4
5
6
-
100
lim by I
-
86.9
Flow CHW Lo
Flow CHW Hi
2960
3500
2500
3000
3150
3650
3100
3350
3700
3700
Design RTon
RTon Lo
RTon Hi
1,250
1,199
1,418
1,250
938
1,125
1,250
1,134
1,314
1,250
1,116
1,206
1,250
1,526
1,526
RTon Average measured
RTon Average at 100%
1,308
1,504
1,031
1,142
1,224
1,249
1,161
1,267
1,526
1,629
0.58
0.53
0.45
0.49
0.58
0.70
0.59
0.64
0.58
0.63
0.54
0.59
0.58
0.60
0.55
0.58
0.58
0.45
0.45
0.45
Design kW/Ton
Efficiency Lo
Efficiency Hi
Efficiency Avg
Filling in other trended data revealed questionable results
‹#› Insert
NoteFooter
:
Per Others Data, all Chillers are peformance within design or better !!
Chiller efficiency too
good to be true !!
Typical overkill is educational…..
Cooling Tower
CWP
CHWP
Cooling Tower
CWP
CHWP
Cooling Tower
CWP
CHWP
Chiller 300 RT
Chiller 300 RT
Chiller 300 RT
Transformer 1,000 KVA
Total Electrical: 3000KVA
Total Cooling: 900RT (Actual Use= 250RT)
Actual Use: 350KVA (Best Practice= 200KVA)
System kW
Comparison of System kW (Before & After)
System kW (Before – 25th Nov to 19th Dec 2006)
Savings in kW
System kW (After – 1st May 2007 to 14th May 2006)
Chilled Water Ton
Singapore Post Centre
System Efficiency (kW/Ton) – Daily/Weekly Analysis
For the week: 15-June-2007 to 21-June 2007
35,000
0.6000
0.5900
30,000
0.5800
25,000
0.5700
0.5600
20,000
0.5745 kW/Ton
0.5670 kW/Ton
0.5688 kW/Ton
5,000
0.5830 kW/Ton
10,000
0.5840 kW/Ton
0.5753 kW/Ton
15,000
0.5758 kW/Ton
0.5500
Ton-hr
kW-hr
kW/ton
0.5400
0.5300
0.5200
0.5100
0
Fri
Sat
Sun
Mon
Tue
Wed
0.5000
Thu
15-Jun-07
16-Jun-07
17-Jun-07
18-Jun-07
19-Jun-07
20-Jun-07
21-Jun-07
Average
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
25,165
14,468
0.5755
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 .
Cheaper way found to make sea water
drinkable—Straits Times, 24June2008
…...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.
.
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
Making Energy Efficiency Accountable
Right now there is no off-the-shelf delivery
process in place to develop truly effective energy
efficiency improvements with long term
performance assurance.
Thomas Hartman, P E
The Hartman Company
June 2007,
automatedbuildings.com
Ashrae--Chiller Plant Efficiency
New Technology
All-Variable Speed
Chiller Plants
EXCELLENT
High-efficiency Conventional
Older Chiller
Optimized
Code Based
Plants
Chiller Plants Chiller Plants
GOOD
FAIR
Chiller Plants with
Correctable Design or
Operational Problems
NEEDS IMPROVEMENT
kW/ton 0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
C.O.P. (7.0) (5.9) (5.0) (4.4) (3.9) (3.5) (3.2) (2.9)
AVERAGE ANNUAL CHILLER PLANT EFFICIENCY IN KW/TON (C.O.P.)
(Input energy includes chillers, condenser pumps, tower fans and chilled water pumping)
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
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)

Fast, Simple, Proven, what`s holding us back

Transcription

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