Professional Documents
Culture Documents
May 2014
CONTENTS
Chapter
No.
Description
Page No
Executive Summary
Introduction
II
Acknowledgment
III
IV
Observations
37
VI
53
VII
Annexure
56
VIII
Backup Calculations
70
Total No of Pages: 89
EXECUTIVE SUMMARY
TSI Business Parks (Hyderabad) Pvt. Ltd. WaveRock, located in
Hyderabad adjacent to the financial district at Gachibowli, is being developed
as a world-class IT/ITES Special Economic Zone campus that serves over
20,000 professionals. The Phase I of WaveRock, known as Bar Building,
encompasses 0.7 million square feet, is currently operational and is completely
leased out. Phase II of the project is currently under development.
TSI Business Parks (Hyderabad) Pvt. Ltd. has incorporated several energy
conservation aspects at the design stage itself resulting in energy efficient
operation. Subsequently, more measures have also been identified and
implemented. Few of them are installation of energy efficient centrifugal
chillers by design, installation of double glazed glasses, LED and T5 lamps in
the entire building, maintaining power factor of 0.99, installation of VFD for
chilled water pumps, cooling tower fans and AHUs etc.
CII Godrej GBC Energy Audit Team have conducted a Detailed Energy Audit
at TSI Business Parks (Hyderabad) Pvt. Ltd. The Energy audit was
conducted from 25th Nov2013 to 05th Dec 2013.
The detailed energy audit included detailed data collection, power
measurements of major electrical energy consumers, analysis of data and
identification of specific energy saving proposals.
The plant and CII energy team have together identified an annual energy
savings potential of Rs. 75.47 Lakhs based on present energy cost (Rs.
5.30/kWh).
The summary of annual savings identified is as follows:
No. of
Proposals
Annual
savings
10
75.47
22.87
52.60
54.06
Details
Total Annual savings
13
CHAPTER - I
INTRODUCTION
TSI Business Parks (Hyderabad) Pvt. Ltd., evinced interest in availing the
services of Confederation of Indian Industry for conducting a detailed energy
audit in their facility.
This report on the detailed energy audit carried out at TSI Business Parks
(Hyderabad) Pvt. Ltd., is in accordance with CIIs proposal dated 14 th Aug
2013, agreed by TSI Business Parks (Hyderabad) Pvt. Ltd. vide their work
order No. TSIBPH/PHASE 2.1/SA/2013/PMWEB/00-040-04.010110/OPO-1451
dated
30th
Sept
2013
and
its
amendment
TSIBPH/PHASE
2.1/SA/2013/PMWEB/00-040-04.010110/OPO-1451-R1 dated 24 th March
2014.
The detailed energy audit comprised of the following activities:
Detailed data collection of power consuming equipments and their design
and operating parameters.
Power measurements of major electrical energy consumers.
Measurement of efficiency of major power consuming equipment such as
pumps, chillers etc.,
Analysis of collected data and measurements to develop specific energy
saving proposals.
Discussion with the facility personnel on the identified proposals.
Presentation on the findings of detailed energy audit to facility personnel.
We are pleased to mention that all the identified energy savings proposals
have been discussed with the facility management team of TSI Business Parks
(Hyderabad) Pvt. Ltd., before finalizing the projects.
The contents of the report are based on the data provided by TSI Business
Parks (Hyderabad) Pvt. Ltd. facility personnel during the detailed energy audit.
The facility personnel should implement the suggestions made in the report
after verifying safety aspects. It is the responsibility of the facility personnel to
observe statutory regulations, if any, as applicable to the facility.
CHAPTER - II
ACKNOWLEDGMENT
CII acknowledges with thanks the co-operation and the hospitality extended to
the CII energy audit team during the detailed energy audit at TSI Business
Parks (Hyderabad) Pvt. Ltd.
The interactions and deliberations with TSI Business Parks (Hyderabad)
Pvt. Ltd. team were exemplary and the whole exercise was thoroughly a
rewarding experience for CII.
The arrangements and support during the energy audit were excellent. We
deeply appreciate the interest, enthusiasm and commitment of TSI Business
Parks (Hyderabad) Pvt. Ltd. towards the energy conservation
We would also like to place on record our sincere thanks and appreciation for
all the senior executives.
CHAPTER III
LIST OF ENERGY SAVING PROPOSALS
Sl.
No
Annual Savings
(Rs.Lakhs)
Investment Required
(Rs.Lakhs)
Payback Period
(Months)
5.20
NIL
Immediate
15.90
NIL
Immediate
3.39
8.00
28
0.08
NIL
Immediate
0.19
0.35
23
0.95
0.85
11
8.48
11.00
16
1.69
NIL
Immediate
21.73
19.50
11
0.25
0.88
42
10
17.61
13.48
10
75.47
54.06
Total
Details
No. of Proposals
Annual savings
10
75.47
22.87
52.60
54.06
13
Chapter - IV
Energy Saving Proposals
-16 mmWC
p = 11
p = 14
Sensor
p = 2
Fire and smoke damper
p = 2.5
Pre-filter
20 mmWC
p = 3
p = 1
-3 mmWC
p = 5
-8 mmWC
22 mmWC
25 mmWC
Sound attenuator
Cooling coil
AHU
BTU/Hr
Static
Pressure,
Pa
TR
826230
68.85
384.00
10
616120
51.34
1.80
11
635880
52.99
300.00
603700
50.31
501580
41.80
120.00
12
597200
49.77
320.00
569900
47.49
150.00
13
807480
67.29
430.00
758660
63.22
500.00
14
479090
39.92
500.00
541670
45.14
500.00
15
607070
50.59
181.00
583210
48.60
450.00
16
677800
56.48
499.00
124970
10.41
176.00
17
529420
44.12
320.00
87550
7.30
NA
18
469308
39.11
480.00
19
663230
55.27
337.00
42
173850
14.49
500.00
20
583450
48.62
106.00
43
NA
NA
30.00
21
267427
22.29
44
NA
NA
115.00
22
484000
40.33
470.00
45
NA
NA
162.00
23
409860
34.16
460.00
46
NA
NA
2.50
24
594460
49.54
300.00
25
934220
77.85
480.00
26
676590
56.38
180.00
27
639820
53.32
240.00
28
520420
43.37
340.00
29
782360
65.20
280.00
30
716410
59.70
415.00
31
502190
41.85
250.00
32
600190
50.02
475.00
33
603720
50.31
102.00
34
586560
48.88
500.00
35
370161
30.85
35.00
36
465402
38.78
115.00
37
692220
57.69
200.00
38
649220
54.10
200.00
39
500090
41.67
380.00
40
460700
38.39
500.00
41
102686
8.56
500.00
The static pressures of majority of the AHUs (as mentioned in the table)
were found to be operating in the range of 380 500 Pa. The values of
static pressure which are operating higher than 220 Pa have been
highlighted in grey color in the table above. This higher static pressure
was maintained with the help of a static pressure set point from the BMS.
The BMS signal of maintaining static pressure set point was manually
entered to a value of 500 Pa. In order to maintain this high static
pressure; all the AHU fan VFDs are running at its maximum cut off point
of 45 Hz.
Operating VFD at higher frequency of 45 Hz leads to increased air flow,
which in turn leads to lower retention time of air in the cooling coil. This
leads to lesser cooling effect in AHUs. The power consumed by AHU fans
also increases, when the VFD is operated at 45 Hz.
The static pressure set point of the fans can be reduced atleast to 270 Pa,
which will reduce the operating speed of the fan with the help of VFD and
will also result in reduced power consumption of AHU fans. The power
consumed by centrifugal fans is proportional to the square of the head
developed by the fan. Changing static pressure set point closer to the
design value will facilitate in reduced power consumption. The value of
270 Pa is taken to obtain the energy savings on a conservative basis.
Recommendations
We recommend the following:
Change the static pressure set point of all AHUs to 270 Pa
o The VFD of AHU fans will automatically operate to achieve the
static pressure
o Atleast 33 kW can be saved in all AHU fans
Once the fans are operating at 270 Pa discharge pressure successfully,
the static pressure value can be set to operate close to the design
value of 220 Pa.
Benefits
The saving potential of 33 kW is available. The annual saving potential of
Rs. 5.20 Lakhs is possible. There is no investment required for this
proposal.
This required flow of 817 m3/h is achieved only when all 3 cooling towers
are in operation.
No. of
cooling
towers in
operation
Total
Condenser
water flow
Condenser
water flow
through
chiller
DX plate
heat
exchanger
Required
flow through
chillers
(m3/h)
(m3/h)
(m3/h)
1
600
490
110
817
730
540
190
817
1064
854
210
817
Maintaining
lesser
condenser
water
flow
than
manufacturers
recommendation may lead to low sub cooling and Compressor surge
tripping. Due to low sub cooling the power consumed by the chiller
compressor increases and the additional cooling capacity which can be
obtained from sub cooling is not available.
Currently it has been observed that the sub cooling in the chiller was
very low and was not more than 0.5 oC. It was observed from the alarms
in the chiller panel that the compressor was tripping as it is reaching the
surge limit. At surge limit the centrifugal compressor reaches its peak
head capability. The system pressure after the compressor is higher than
the pressure generated by the compressor and the fluid tends to flow
back into the compressor. This surge phenomenon repeats in cycles.
Consequently, the compressor loses the ability to maintain peak load and
the system becomes unstable resulting in compressor tripping in order to
the safeguard the compressor. Surging will also result in overheating of
the compressor.
Maintaining the condenser water flow at 817 m3/h, by operating all three
cooling towers will improve the sub cooling of the refrigerant and will
also avoid surge tripping of the chiller compressor.
Proposed system
As explained earlier it is recommended to utilize all three cooling towers
and operate all the cooling tower fans with VFD control.
Utilizing all three cooling tower will help us in utilizing the additional
heat transfer surface area, which is available in the cooling towers
which are currently in stand by condition. Also, utilizing all cooling
towers will help us in maintaining the required amount of condenser
water flow for the chillers and will improve the sub cooling of the
chillers.
There is a good opportunity to improve the air water contact ratio in the
cooling tower by running all the cooling tower fans and operating them
with VFD. The sump temperature of the cooling tower can be given as a
feedback to the VFD of the cooling tower fans. The above mentioned
steps can be followed to obtain an approach of 4 oC, consistently in all the
cells of the cooling tower.
Recommendation
With the above background, to optimize the operation of cooling towers, it
is recommended to
Operate all the three cooling towers
Operate all the fans in auto mode with sump temperature as feedback
for VFDs. Instead of operating two fans at full speed, operating 4 fans
at 25% percent speed would result in significant amount of power
savings
Benefits
The estimated annual savings by optimizing the cooling
performance is Rs. 15.90 Lakhs without any investment.
tower
SHGC (%)
6 W/m2/K
86
Double glazed
1.3 3 W/m2/K
76-63
50-26
Hence selecting the right glass is important in reducing the heat load of a
given conditioned space. An alternative to replacing double glazed glass is
coating the glass windows and doors with insulation paints (nansulate).
The insulation paints have properties like corrosion resistance, high
adhesion and translucence. By adequate no. of insulation paint coats, the
performance of a double-glazed glass can be matched with a triple-glazed
glass without any significant reduction in visible light transmittance.
Recommendation
We recommend coating glass area in the building with translucent
insulation paints. A heat transfer co-efficient value of at least 0.7 W/m2/K
can be achieved.
Benefits
The estimated annual savings by coating the glass surface area with
insulation paints is Rs. 3.39 Lakhs. The investment required is Rs. 8.00
Lakhs with a simple pay back period of 28 months.
9-24 m3/hr
Design Head
163-72 meters
Design kW
11 kW
Flow
28.4 m3/hr
Head
63 meters
Power Consumed
10.5 kW
65 meters
Design Flow
28 m3/hr
8.6 kW
Recommendation
Step 1:
We recommend the following changes in the domestic transfer pump:
1. Close the bypass valve completely, thereby bypassing the hydro
pneumatic system and the recirculation.
This will result in reduction of recirculation flow back to the domestic
water but also decreases the overall flow due to increase in the back
with
an
energy
efficient
Design Head
65 meters
Design Flow
28 m3/hr
8.6 kW
pump
with
design
Benefits
The annual energy saving potential by installing a new pump is Rs. 0.19
Lakhs considering 5 hours of operation per day. The investment required
for installing a new pump is Rs. 0.35 Lakhs with a payback period of 23
months.
It was observed during the audit that the cooling water requirement to
the plate heat exchangers is being catered by the condenser pumps
installed for main chiller system. The total flow of the condenser pump
during the audit was 730 m3/hr out of which 540 m3/hr (74%) is flowing
through the chiller condenser and 190 m3/hr (26%) is flowing through
the plate heat exchanger.
The operating efficiency of the chilled water pump during the audit was
calculated as 43%. As the pump is designed for a head of 30 m and only
12 m head is required for the pump, the pump is operating in an
inefficient zone.
Design Head
15 meters
Design Flow
550 m3/hr
Design Power
30.2 kW
80%
Proposed System
The chilled water system can be separated for both the bar building and
phase 2.1. Currently the lines of bar and phase 2.1 are interconnected;
this results in additional losses due to valve throttling in bar building.
Seggregating the lines and pumps for chilled water for bar building and
phase 2.1 will enable us in avoiding the loss due to valve throttling.
Excluding the loss across the valve throttling, the loss across the system
would be the pressure drop across the chiller and due to the back
pressure developed by the operation of auto control valves in the building.
After segregating the pump and lines of bar and phase 2.1 the same
pump can be used for phase 2.1 as well, as the pump is designed based
on the flow requirement of chiller. Flow of both the pumps can be
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
maintained with VFD and based on TR load required on the building. The
TR load required for each building can be obtained from TR load required
for each AHU. The total flow maintained through the chiller can be on the
basis of operating TR load.
Benefits
The annual energy saving potential by segregating both the chilled water
systems and installing new pumps is Rs. 8.48 Lakhs per annum. The
investment required for installing a new pump with VFD is Rs. 11.00
Lakhs with a payback period of 16 months.
2500
KVA
2500
KVA
2500
KVA
OFF
OFF
433 V
6257 Watt
Load Loss
17645 Watt
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
Power
PF avg
Running
kVA
% loading
T/F loss
KW
T/F- 1
418.91
878
0.99
887
35
8.42
T/F- 2
417.70
615
0.98
625
25
7.36
T/F- 3
418.62
755
0.99
762
30
7.84
Total Loss
~ 24 KW
The optimal loading on transformers occur at the point when the No-load
loss = Load losses (which is around 60%)
For the transformers installed at TSI Waverock, the optimal loading point
is calculated and found to be around 60%.
Hence it is recommended to operate two transformers instead of three.
This would result in
Optimal loading on each of the two transformers
Reduction in transformer losses from around 24 KW to 20 KW.
Proposed Scenario
It is recommended to shift the entire load to two transformers. The third
transformer needs to be switched off and the primary of this transformer
should be isolated from the supply.
33 KV
2500
KVA
2500
KVA
2500
KVA
ON
OFF
433 V
Transformer
loss KW
T/F- 1
60
12.6
T/F- 2
T/F- 3
30
7.8
Total Loss
~20 KW
Benefits
The estimated annual savings by switching off one transformer and
shifting the entire load to two transformers is 1.69 Lakhs without any
investment.
Lumen/Watt
CRI
Life hours
Fluorescent lamps
50
Good (67-77)
5,000
LED lamps
120
50,000 1,00,000
High S/P ratio: LEDs have higher scotopic/photopic ratio (S/P ratio).
The eye has two primary light sensing cells called rods and cones cones
function in day light and process visual information whereas rods function
in night light. The cone dominated vision is called photopic and the rod
dominated vision is called scotopic. The S/P ratio indicates the measure of
light that excites rods compared to the light that excites cones. In office
environments, illumination is more effective if the S/P ratio is high as it is
under scotopic region. LEDs hence are ideally suited for these applications
as they have a high S/P ratio.
Longer life time: LEDs have longer life time of around 1,00,000 hours.
This is equivalent to 11years of continuous operation or 22 years of 50%
operation.
Type
Lumen/Watt
CRI
Life hours
CFLs
60
8,000 -10,000
LED lamps
120
50,000 -1,00,000
High S/P ratio: LEDs have higher scotopic/photopic ratio (S/P ratio).
The eye has two primary light sensing cells called rods and cones cones
function in day light and process visual information whereas rods function
in night light. The cone dominated vision is called photopic and the rod
dominated vision is called scotopic. The S/P ratio indicates the measure of
light that excites rods compared to the light that excites cones. In office
environments, illumination is more effective if the S/P ratio is high as it is
under scotopic region. LEDs hence are ideally suited for these applications
as they have a high S/P ratio.
Longer life time: LEDs have longer life time of around 1,00,000 hours.
This is equivalent to 11years of continuous operation or 22 years of 50%
operation.
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
CRI
Life hours
CFLs
60
8,000 -10,000
LED lamps
120
High S/P ratio: LEDs have higher scotopic/photopic ratio (S/P ratio).
The eye has two primary light sensing cells called rods and cones cones
function in day light and process visual information whereas rods function
in night light. The cone dominated vision is called photopic and the rod
dominated vision is called scotopic. The S/P ratio indicates the measure of
light that excites rods compared to the light that excites cones. In office
environments, illumination is more effective if the S/P ratio is high as it is
under scotopic region. LEDs hence are ideally suited for these applications
as they have a high S/P ratio.
Longer life time: LEDs have longer life time of around 1,00,000 hours.
This is equivalent to 11years of continuous operation or 22 years of 50%
operation.
Faster switching: LED lights reach its brightness instantly upon
switching and can frequently be switched on/off without reducing the
operational life expectancy.
Greater durability and reliability: As LEDs are solid-state devices and
uses semi-conductor material; they are sturdier than conventional
sources that use filaments or glass. LEDs can also withstand shock,
extreme temperatures and vibration as they dont have fragile materials
as components.
Good Colour Rendering Index (CRI): The color rendering index, i.e.,
measure of a light sources ability to show objects as perceived under
sunlight is high for LEDs. The CRI of natural sunlight is 100 and LEDs offer
CRI of 80 and above.
LED offers more focused light and reduced glare. Moreover, it does not
contain pollutants like mercury
LED technology is highly compatible for solar lighting as low-voltage
power supply is sufficient for LED illumination.
Recommendation
It is recommended to replace the 4 X 14 W CFLs and 2 X 18 W CFLs with
30 W LEDs and 2 X 9 W LEDs respectively.
Benefits
The estimated annual savings that can be obtained by replacing CFL
lamps with LEDs is Rs. 17.61 lakhs. The investment required is Rs.
13.48 lakhs. The payback period is 10 months.
Chapter - V
Observations
OBSERVATION NO. 1
- 17 mmWC
271.39 Pa
AHU
Return air
Supply air
21236.86 CFM
4.95 kW
Pre Filters
Bag filters
Without Bag
Filter
- 8 mmWC
Fresh air
374.39 Pa
AHU
Return air
Supply air
24188.20 CFM
5.07 kW
Pre Filters
The AHU fans are installed with pre filters and bag filters in order to
maintain the indoor air quality as shown in the fig. above. The bag filter
type MERV 13, is used as per green building standards in order to avoid
dust accumulation in the indoor area.
Trial Taken
A trial was taken for one AHU fan (AHU # 29) to observe the effect of the
bag filter on the fan. In the trial, the pressure is observed after the fan in
two scenarios: with and without bag filters:
Pressure with bag filter
-17mmWC
-8 mmWC
It has been observed that once the bag filter was removed the static
pressure at fan outlet has increased to 373.39 Pa from 271.39 Pa. In
order to achieve the same discharge pressure at fan outlet, the fan speed
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
was reduced with VFD so that 270 Pa can be achieved. The results of
discharge pressure with speed reduction, along with measured power at
that speed are shown in the table below:
Suction
pressure
after filter
VFD
Frequency
Discharge
pressure
from BMS
Measured
power
mmWC
Hz
Pa
kW
-5
30.5
67.29
1.83
-6
35.7
149.29
2.64
-7
40
243.96
3.75
-7
41
277.91
3.96
-8
43
306.21
4.47
OBSERVATION NO. 2
The CO2 sensors with default value of 2000.6 indicate the higher value of
CO2 in that AHU return air. Hence, the fresh air damper always remains
open for those AHUs. If fresh air damper remains open continuously, then
the outside air from atmosphere which is needed to be cooled will
increase the load on the chiller. Hence, power consumption of chiller will
increase. The CO2 sensors with zero value indicate that there is no CO 2 in
the return air. Hence, the fresh air damper remains close for those AHUs.
If fresh air damper remains close always, then there is no fresh air supply
to rooms, resulting in negative impact on the indoor air quality and
comfort of the people.
The level of CO2 in indoor air should be less than 700 ppm. Hence, it is
recommended to set the set point for CO 2 sensors as 700 ppm. If CO2
level increases more than 700 ppm the fresh air damper should open in
order to lower the CO2 level and if CO2 level is less or equal to 500 ppm,
the fresh air damper should remain close.
Recommendations
We recommend repairing all identified faulty CO 2 sensors. In order to
maintain the CO2 level less than 500 ppm in the room, set point for CO 2
should be 500 ppm. If CO 2 level increases more than 500 ppm, the fresh
air damper should open and vice versa.
Benefits
The replacement of faulty CO2 sensors will improve the indoor air quality
and also improve the loading on chiller by controlling the fresh air supply.
OBSERVATION NO. 3
INSTALL AMBIATORS
CAFETERIA
IN
PLACE
OF
AHUs
OF
During the detailed energy audit at TSI Waverock, the food court were
studied in detail for possible energy saving opportunities. The following
are the observations made.
Present status
Presently air conditioning in cafeteria is catered by two AHUs and 35 TR is
the installed chiller load. The room temperature is expected to be
maintained around 24 to 26C.
It is always recommended to maintain fresh air circulation in the cafeteria
as it reduces the recirculation of air and helps in reducing the toxins in the
air.
There is a good potential to substitute the chilled water AHUs with
ambiators in the cafeteria. The temperatures which can be attained by
using ambiators is 24 to 28oC (varies depending on seasons). An ambiator
reduces the temperature of circulating air in two stages:
Working Principle of Ambiator
Sensible Heat Exchanger (Stage 1): The air from the atmosphere is
sucked in through 20 micron (standard norms) dust filters and is forced
across a heat recuperator consisting of a cross flow, wet plate plastic heat
exchanger, which has an efficiency of about 60%.
The air that flows through the heat exchanger is never in direct contact
with water (which is passing on the other side of the heat exchanger).
The wet side of the heat exchanger is covered with a hydrophilic material,
which maintains a thin film of water that evaporates when the sensible
heat is transferred to the wet side.
A portion of the cooled air picks up the evaporating water and exhausts
out. About 15 20% of the total air available is used up this way. The air
that comes out of this heat exchanger will be significantly colder than the
ambient.
Adiabatic Heat Exchanger (Stage 2): The air that is coming from the
heat recuperator is then passed through an evaporative cooling module,
which consists of a cellulose media made up of a speciality material called
Celdek, which is constantly kept wet with a water drip.
Part of the sensible heat in the air is converted into latent heat and the air
is finally delivered in to the conditioned space at significantly lower
temperature than the intake.
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
Limitations
Unit
kW / TR
Conventional
0.6 1.0
Ambiator
0.2 0.3
OBSERVATION No. 4
REPLACE THE DOUBLE GLAZED
CONDENSATION IS OBSERVED
GLASSES
WHERE
OBSERVATION No. 5
Voltage (V)
Load (kW)
MDB 9
241
50.7
MDB 11
241
26.8
lamps
is
maintained
as
specified
by
the
Proposed Scenario
By maintaining the voltage at 210 V, 12.5 % of the power can be saved.
Hence it is suggested to install lighting transformers at the above
locations and maintain the voltage at 210 V.
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
Voltage (V)
Power
(kW)
Connected Recommended
Load
transformer KVA
(kW)
rating
MDB 9
241
50.71
276
400
MDB - 11
241
26.84
138
200
OBSERVATION No. 6
Longer life time: LEDs have longer life time of around 1,00,000 hours.
This is equivalent to 11years of continuous operation or 22 years of 50%
operation.
Faster switching: LED lights reach its brightness instantly upon
switching and can frequently be switched on/off without reducing the
operational life expectancy.
Greater durability and reliability: As LEDs are solid-state devices and
uses semi-conductor material; they are sturdier than conventional
sources that uses filaments or glass. LEDs can also withstand shock,
extreme temperatures and vibration as they dont have fragile materials
as components.
Good Colour Rendering Index (CRI): The color rendering index, i.e.,
measure of a light sources ability to show objects as perceived under
sunlight is high for LEDs. The CRI of natural sunlight is 100 and LEDs offer
CRI of 80 and above.
Recommendation
It is recommended to replace the existing 70 W HPSV lamps with 1X18 W
LEDs. A 1.5 kW capacity solar panel can be installed and the requirements
of street lighting can be met through renewable energy.
OBSERVATION No. 7
UTILIZATION
FACILITY
OF
WATER
IN
TSI
WAVEROCK
Background
During the detailed energy audit at TSI Waverock, detailed water
conservation study was conducted for possible water savings.
There are two water sources for the facility. One from Municipal
Corporation and the other is from ground water. The inlet from the
municipal line and ground water directly goes to the fire water tanks
(2nos. of 100 KL each). The overflow from Fire water tank goes to the
Raw water tanks (2nos. of 175 KL each). From the raw water tank, water
is passed through sand filter and carbon filter before storing it in the
Domestic water tanks (2 nos. of 175 KL each). Water is pumped to two
overhead tanks on the terrace from the domestic water tanks for
domestic purposes in the facility. There is also an alternate supply line
from the domestic water tank to the softener tank through a softener. The
softener tank water is pumped to the cooling towers as cooling tower
makeup water. However, the cooling tower makeup water is mainly
catered by the treated STP water. The water from softener tank is used
only as a backup.
Fresh water from the overhead tank is mainly used for toilets and kitchen
areas in the facility. The water from these areas are treated in the STP
and then passed through the sand filter, carbon filter and softener and
checked for hardness before using it in the cooling tower as makeup
water. A portion of the treated STP water is used for gardening purposes.
CII congratulates the plant team for efficient utilization of water in
recycling and using it for cooling tower makeup and for gardening
purposes.
Shift wise consumption details of water consumption for cooling tower
makeup and for gardening and the power consumed for the pumps is also
monitored in every shift. CII congratulates the facility management for
the good practice followed in the facility.
Major loss of water in the entire system is the cooling tower blowdown
and evaporation losses. In TSI Waverock, the cooling tower blowdown is
automatic depending on the conductivity of the water measured by
installed conductivity sensors.
During the detailed energy audit, the blowdown losses and the
evaporation losses are calculated to analyze the cooling tower operation
and water losses in the cooling tower.
600
730
1064
The evaporation losses in all three cases (i.e. 1 CT running, 2 CTs running
and 3 CTs running) are calculated as follows:
Evaporation loss with 1 CT
=
=
3.67 m3/hr
88 m3/day
=
=
4.46 m3/hr
107 m3/day
=
=
6.51 m3/hr
156 m3/day
=
=
204 88
116 m3/day
=
=
204 107
97 m3/day
204 156
48 m3/day
=
=
1 + (88/116)
1.75
=
=
1 + (107/97)
2.10
=
=
1 + (156/48)
4.25
CHAPTER - VI
5.1
recommended
proposals
and
reap
the
5.2
Specific Recommendation
TSI Business Parks (Hyderabad) Pvt. Ltd. should form an energy
conservation committee. The committee should consist of senior
operating, electrical and maintenance personnel.
The committee should meet once in a month with a specific agenda
to review the progress of implementation of proposals and to guide
the implementation team.
The energy manager of TSI Business Parks (Hyderabad) Pvt. Ltd.
should coordinate all the implementation activities. The main
responsibility of implementing the proposals and achievement of
savings should be with the concerned operating and maintenance
personnel and not with the energy manager.
The immediate task of TSI Business Parks (Hyderabad) Pvt. Ltd.
should be to implement the identified proposals and get the
savings.
5.4
Monitoring Of Proposals
All the implemented proposals are to be monitored on a proposalby-proposal basis for actual achievement of savings on a monthly
basis.
5.5
Motivational Aspects
The successful management of energy depends on motivation of
technical personnel and their commitment. For this reason, TSI
Business Parks (Hyderabad) Pvt. Ltd. should carry out the following
motivational aspects to sustain energy conservation activities.
Send operating, electrical and maintenance personnel for training
programs in specific areas like:
Pumps
Fans & Blowers
Refrigeration and Air conditioning
Motors
Lighting
Conduct in-house training programme on energy management.
Organize visits for executives to similar facilities to know the
energy conservation / best operational practices etc.
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
5.6
Conclusions
TSI Business Parks (Hyderabad) Pvt. Ltd. team and CII
energy audit team together have identified 10 proposals for
implementation.
An annual savings potential of Rs. 75.47 Lakhs can be realized
by implementing the recommended proposals
Out of the total savings identified Rs. 22.87 Lakhs can be
achieved without any significant investment.
The remaining savings of Rs. 52.60 Lakhs can be achieved with
an investment of Rs. 54.06 Lakhs which will be paid back in 13
Months.
Implementation of identified proposals should be given top
priority and should be done step by step.
The major supplier address is enclosed as Annexure A
TSI BUSINESS PARKS (HYDERABAD) PVT. LTD.
Assign specific responsibility for implementation of proposals
Monitor savings achieved on a proposal by proposal basis.
Monitor overall power consumption and reduction in energy
consumption equipment-wise
TSI Business Parks (Hyderabad) Pvt. Ltd. should have the
goal of sustaining the status of the energy efficient building.
Chapter VII
Annexure
AnnexureA
SUPPLIER ADDRESS
VFD and other drives
1. Rockwell Automation India
Pvt. Ltd. (Allen-Bradley India
Ltd.)
C - 11, Industrial Area
Site - 4, Sahibabad
Ghaziabad - 201 010
Tel: +91 120 2895245, 2895252
Fax: +91 120 2895226
1.
4.
6.
INDIA.
Tel : +91 022 2423 7777
Fax : +91 022 24382288
5.
2. Excellent Industrial
Instruments
1/63, E Type, SIDCO Nagar
Villivakkam, Chennai 600 049
Tel : 044 26172977
Fax : 044 26172531
Email: xlenergy@vsnl.net
Web: www.xlntenergy.com
Tel : 91-4344276358/278658/276958/276959
Fax: 91-4344-276358/59
3. Beblec India Pvt. Ltd.
III, Anand Estates
J M C Compound
189/A, S G Marg
Mumbai - 400 011
Tel: 022 - 23080078/23073321
Fax: 022 - 23071494
Email: mumbai@beblec.com
Key Personnel
Mr. R. Sekar (Managing Director)
Mobile: +91 - 9448491548,
9844136209, 919448354504
5. Jindal Electricals
390 A, Industrial Area-A,
Ludhiana-141003
Phone : 0091-161-2607271,
2220035, 2600051
Fax : 0091-161- 2600385
E-Mail :je@jindalelectricals.com
9/6, Ist Street, Venkateshwara
Nagar, Adyar
Chennai -600 020, Tamil Nadu,
India.
Phone : +(91)-(44)
24403473/24403476
Fax : +(91)-(44)-24403470
E-mail : consul@vsnl.com,
npkrishnan@consulindia.com
5. Muskaan Engineers
423, Industrial area A
Ludhiana 03
Ph: +91-161-5088381
Fax: 5022381
Mob: 99157-03056, 94170-33948
E-mail:
info@muskaanengineers.com
Tel: +91-124-4081581,
+91-124-4150100
Fax: +91-124-4081577
6. IC NASA LED Lights
Chandmor Agencies 10/76, Old
Anand Nagar
Next toReliance Energy,
Santacruz (E), Mumbai 400
055
Ph: 022 26101930 / 31 / 32,
Fax: 26102419
Contact Person Name
Mona 0 98201 22652
INDUCTION LAMPS
Bajaj Electricals Ltd
H. No. 6-3-1090/2, 3rd Floor
Vithal Das Chambers,
Rajbhavan Road, Somaji guda,
Hyderabad - 500 082
Phone : 040-23442932, 23442933,
23442934
Fax : 040-23302745
Email :
gv.reddy@bajajelectricals.com
naveenk@bajajelectricals.com
Mr. P V Venkatesh
Mob- 08376806624
CAPACITORS
1. Momaya Capacitors
401, Madhav Apartments
Jawahar Road, Opp. Rly. Stn.
Ghatkopar (East)
Mumbai - 400 077
Tel: 022 - 25168281/82,
65754001/02
Fax: 022 - 2516 0758
2. Baron Power
No. 3, Karpagambal Nagar,
Mylapore, Tamil Nadu, India
Ph: +91-44-24356383/84/86,
42131849/50
Fax: +91-44-24356385
3. Meher Capacitors
Confederation of Indian Industry
CIISohrabji Godrej Green Business Centre
3. KLG Systel
Plot No. 70A,
Sector - 34, Gurgaon - 122 004
Haryana (India)
Telephone: +91 (0) 124-4129900
Fax: +91 (0) 124-4129999
e-mail : klg.ho@klgsystel.com
Product Infra red sensor for lighting energy saving
Blue Technologies
61, shreepal chambers, 481/c shaniwar peth,
opp shaniwarwada, Pune - 411030, India.
Tel : +91 20 65209611 T/ F : 24468058,
Cell : +91 9371042444, 9326042444
bluesachin@gmail.com
Email:
subramaniam.ravichandran@cummin
s.com
Neel Controls
#112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W), Mumbai 400 080
Ph: 022 2560 3371 / 2569 5047
Fax: 022 2568 3211
ABB Limited
Khanija Bhavan, 2nd Floor
East Wing, No. 49, Race Course Road
Bangalore - 560 001
Ph: 080 - 22949150 to 54
Fax: 080 - 22949148
Contact Person
Mr. S Ravichandran
General Manager
Mob: 098220 93785
UPS
APC
# 16, Row House, Goyal Inter City
Behind Drive in cinema, Thaltej
Road, Thaltej
Ahmedabad, Gujarat 380 054
India
Ph: (079) 2684 0124/ 324
APC
# 5, Lake Avenue,
Near Mudiali Bus Stop
Kolkata, West Bengal 700 026
India
Ph: (033)2465 5519, 2463 0064
Email: nadiair@vsnl.net
Website: www.nadiindia.com
Low pressure drop flow meters
Emerson Process Management (India) Private Ltd.
D-Wing, 2nd Floor, Modern Mills Compound
Sane Guruji Marg, Jacob Circle, Mahalaxmi
Mumbai 400011
India
Tel +91 22 5662-0566
Fax +91 22 5662-0500
Email : Marcom@EmersonProcess.co.in
Switzer Instrument Limited
9, South Boag Rd. T.Nagar,
CHENNAI (Madras) - 600 017 India
Phone : +91-44-2434 0999/3956/4321
Fax: +91-44-24347887
email: sales@switzerinstrument.com
Chandak Instruments Pvt. Ltd.
G-004, Smruti, Opp. Dhanwatey
National College, Congress Nagar,
Nagpur-440012 (India)
Phone : +91-712-2420025
Fax
: +91-712-2420026
info@chandakinstruments.com
www.chandakinstruments.com
Air conditioning system
United Engineering Corporation
147, R P Road, Secunderabad-500 003
Telefax: 2754-5501, 1113, 3559, 2753-8956
Email: uecajay@gmail.com & hyd2_uecajay@sancharnet.in
Visit: www.smartcool.co.in
Insulations
Megha Insulations Pvt Ltd.
A-11/6th Floor, Dada Saheb Flats
Kalanala, Bhavnagar 364001
Ph: 0278-3004523/26
Fax: 0278-3004728
Email: mipl@meghainsulation.com
Contact Person
Mr H V Shah -98252-07723 & 94262-12823
Mrs. Madhu: 98795-46523
Manoj Telrandhe
Manager Knowledge Based Businesses & ITes
SEE-Tech Solutions Pvt. Ltd.
11/5, Lets Conserve, MIDC InfoTech Park
Near VRCE Telephone Exchange
South Ambazari Road, Nagpur-440 022
Mobile: +91-9975325831
Ph: 0712-2222177
Fax: 0712-2225293
Web: www.letsconserve.org
Email: utisave@gmail.com
seemil_ngp@sancharnet.in
Suppliers for Computational Fluid Dynamics (CFD) Study and Analysis
Mahindra Satyam Technology Centre
Bahadurpally Village
R R Dist, Hyderabad 500 043
Telephone: +91 40 3063 5082
Mr Rahul S. Tamboli
Telephone: 040-3063-5271
Mobile: +91-998-550-6261
Mech-Well Industries Limited
Head Office: Contact person
Mr V T Jadhav
Marketing Executive
Mobile: 09223393614
7 - A, Old Anijrwadi, Mazgaon
Mumbai - 400 010
Tel: +91 - 22 - 2373 74 54
+91 - 22 - 2374 23 54
Fax: +91 - 22 - 2371 94 46
PL Engineering Limited
(A Punj Lloyd Group Company)
76 Institutional Area, Sector 32
Gurgaon - 122001, India
Contact Person
Mr Priya Ranjan Kumar
DGM - Business Development
Mob: 07411021920, Bangalore
Disclaimer
While every care has been taken in compiling this list, Confederation of
Indian Industry does not accepts any claim for compensation, if any entry is
found to be wrong, abbreviated, omitted or inserted incorrectly either as to
the wording space or position in the list. While attempts are being made
continuously to make the list as elaborate, as possible CII wishes to inform
that neither the list of technologies nor list of suppliers for a given product /
technology is comprehensive. The list is only an attempt to create awareness
on energy conservation and sharing of best practices being adopted in Indian
Industry.
Annexure-B
FORMAT FOR MONITORING THE IMPLEMENTATION OF ENERGY SAVING PROPOSALS
Sl.
No
Annual
Savings
(Rs.Lakhs)
Investment
Required
(Rs.Lakhs)
Payback
Period
(Months)
5.20
NIL
Immediate
15.90
NIL
Immediate
3.39
8.00
28
0.08
NIL
Immediate
0.19
0.35
23
0.95
0.85
11
Person/Departmen
t Responsible
Target
Date
Remarks
70
Confederation of Indian Industry
8.48
11.00
16
1.69
NIL
Immediate
21.73
19.50
11
0.25
0.88
42
17.61
13.48
10
75.47
54.06
10
Total
71
Confederation of Indian Industry
Chapter - VIII
Back-up Calculations
Static
Pressure, Pa
Required static
Pressure, Pa
%
loss
Power
saving
500
270
39.32
1.97
500
39.32
1.97
450
30.77
1.54
384
19.49
0.97
11
300
5.13
0.26
12
320
8.55
0.43
13
430
27.35
1.37
14
500
39.32
1.97
16
499
39.15
1.96
17
320
8.55
0.43
18
480
35.90
1.79
19
337
11.45
0.57
22
470
34.19
1.71
23
460
32.48
1.62
24
300
5.13
0.26
25
480
35.90
1.79
28
340
11.97
0.60
29
280
1.71
0.09
30
415
24.79
1.24
32
475
35.04
1.75
34
500
39.32
1.97
39
380
18.80
0.94
40
500
39.32
1.97
Power
Average
power of
AHU ~
5 kW
41
500
39.32
1.97
500 Pa
270 Pa
=
=
500 Pa 270 Pa
230 Pa
=
=
5 kW 39.31%
1.97 kW
Power reduction
=
=
280C
310C
210C
Range is calculated as
Approach of the cooling tower
=
=
For every 10C drop in condenser water temperature, the compressor power will
be reduced by 4 to 5 %.
The power consumption of fans is measured as:
Equipment
Frequency
Hz
Power consumption
in kW
CT-3 fan-2
50.9
6.51
CT-3 fan-1
50.8
6.6
CT-2 fan-4
51.8
12.42
CT-2 fan-3
51.4
10.59
CT-2 fan-1
47
9.6
CT-2 fan-2
51.4
10.83
Total
56 kW
9.4 kW
56.4 kW
2.35 kW
28.2 kW
Savings
=
=
56.4 28.2 kW
28.2 kW
By operating all the three cooling towers and CT fans, the cooling tower outlet
temperature could be achieved close to 250C.
For every 10C drop in condenser water inlet temperature, the compressor
power will be reduced by 4 %.
For a 30C drop in condenser water inlet temperature, there would be a power
reduction of at least 12%.
Considering 30C drop in condenser water inlet temperature, the saturation
temperature of refrigerator is reduced to 28.10C and the saturation pressure
also reduces correspondingly.
On an average, a pressure reduction of at least 100 kPa is possible from the
existing 750 kPa.
Pressure P2 at sat. temperature of 310C
750 kPa
650 kPa
P2-P1_
P2+P0
=
=
532 kW
=
=
0.117 X 532 kW
62.01 kW
Total savings in KW
=
62.01+28.2 kW
=
around 90 kW
On a conservative basis, 75 kW of power reduction is considered to estimate
the savings.
Confederation of Indian Industry
Annual savings in Rs
=
=
=
Investment
Nil
Payback period
Immediate
=
=
Savings in Refrigeration
4.8 W/m2
1000 x 3.516
0.0014 T.R/ m2
=
=
=
Investment
=
=
=
Rs. 45/m2
Rs. 45/m2 x 17600 m2
Rs. 7,92, 000 = ~ Rs. 8 Lakhs
Payback Period
Rs. 8 Lakhs x 12
Rs. 3.39 Lakhs
28 months
9-24 m3/hr
Design Head
163-72 meters
Design kW
11 kW
Flow
28.4 m3/hr
Head
63 meters
Power Consumed
10.5 kW
The static head of the pipeline is approximately 65 meters. This indicates that
there is a mismatch between the design specifications and the actual
requirement in pump operation. Therefore the pump is throttled to 50% to
avoid excess flow and tripping of the motor. The present operating efficiency of
the pump is 51.5%
A new proposed pump with the new design parameters reduces the power
consumption by 19% and operates with close to design operating efficiency.
Step 1:
We recommend the following changes in the domestic transfer pump:
2. Close the bypass valve completely, thereby bypassing the hydro
pneumatic system and the recirculation.
This results in reduction of recirculation flow back to the domestic water tank.
The recirculation from the pump is estimated at 8.5% of pump discharge. The
recirculation line has to be closed by closing the recirculation valve.
Power is directly proportional to the flow of the pump,
Confederation of Indian Industry
10.5 kW
Saving Potential
=
=
0.085 x 10.5 kW
0.89 kW
Savings
=
=
65 meters
Design Flow
28 m3/hr
8.6 kW
Design Efficiency
65%
10.5 kW
=
=
28 m3/hr x 61 m
102 x 3.6 x .65 x 0.85
8.4 kW
Savings
2.0 kW
Cost Savings
Investment
=
=
=
Payback
=
=
SEGREGATE
CHILLERS
CHILLER
CONDENSER
SYSTEM
AND
DX
During the audit, it was observed that separate plate heat exchangers and
supplementary cooling water pumps are installed for the water cooled
packaged DX chillers. The DX chillers are used for two lift rooms on the
terrace, in the gym and recreation areas in 2 floor and electrical load centers
in the same floor.
It was observed during the audit that the cooling water to the plate heat
exchangers are being catered by the condenser pumps installed for main
chiller system
Total Condenser water flow
730 m3/hr
540 m3/hr
190 m3/hr
Supplementary cooling water pump design and operating parameters are given
below:
Design
Operating
Flow -
103 m3/hr
Head -
25 meters
Power 18.5 kW
Power-
8.5 kW
VFD is installed for the supplementary cooling water pump and the frequency
is maintained at 41 Hz during the audit. Still, the delta T across the plate heat
exchanger was measured to be 0.3oC which suggests that there is excess
cooling water flow in the plate heat exchangers.
Segregating the condenser water system avoids the 190 m3/hr condenser
water flow through the PHE and the same flow can go through the chiller
condenser and increase the performance of the chillers.
Recommendation:
We recommend segregating the chiller cooling water system and the DX
chillers cooling water system by installing a separate pipeline to the cooling
tower from the DX chillers.
Advantages of segregation:
1. Higher flow through chiller condenser results in compressor power
saving
Confederation of Indian Industry
of
following
Design Head
25 meters
Design Flow
40 m3/hr
Design Power
5.8 kW (pump)
Design Efficiency
55%
=
=
40 m3/hr x 25 m
102 x 3.6 x .60 x 0.85
5.33 kW
8.5 kW 5.33 kW
3.17 kW
Say 3.0 kW
Power Savings
Cost Savings
Investment
and piping cost)
Payback
=
=
=
=
=
15 meters
Design Flow
550 m3/hr
Design Power
30.2 kW
Design Efficiency
80%
The chilled water flow to be controlled with VFD with chiller loading as the
feedback
We recommend installing a separate chilled water pump with VFD for phase
2.1 with the design specifications:
Design Head
15 meters
Design Flow
550 m3/hr
Design Power
26 kW
Design Efficiency
75%
The chilled water flow in both the chilled water pumps is to be controlled with
VFD having chiller loading as the feedback.
It is assumed that around 300 m3/hr of chilled water is flowing through the
bar building. During the audit it was observed that, only one floor of the Phase
2.1 is in operation. The bar building was completely in operation. The quantity
of the chilled water flow was found to be close to 600 m 3/h. In order to achieve
the savings conservatively, we have assumed only 300m 3/h of water is flowing
through the bar building.
=
=
Say 20.0 kW
Installing an energy efficient pump with design specification as above, the new
pump power consumption would be
New Pump Power consumption
51.5 kW 31.2 kW
20.3 kW
40 kW
Savings
=
=
=
Payback
Power Savings
33 KV
2500
KVA
2500
KVA
2500
KVA
433 V
The three transformers are identical and the no-load and full-load losses from
the test certificate are as follows:
No-Load loss
6257 Watt
Load Loss
17645 Watt
The percentage loading on each of the transformer and the transformer losses
were calculated as follows:
% Loading
Running KVA
Rated KVA
Transformer Loss in kW
Running %
loading
kVA
running
kVA/2500
T/F- 1
887
887/2500 = 35 %
8.42
T/F- 2
625
625/2500 = 25 %
7.36
T/F- 3
762
762/2500 = 30 %
7.84
Total kW ~ 24
Proposed Scenario
It is recommended to shift the entire load to two transformers and operate
them in parallel. The third transformer needs to be switched off and the
primary of this transformer should be isolated from the supply.
33 KV
2500
KVA
2500
KVA
2500
KVA
433 V
The transformer losses in the proposed scenario are calculated as:
Confederation of Indian Industry
%
loading
running
kVA/2500
in
T/F- 1
60
12.6
T/F- 2
T/F- 3
30
7.8
TOTAL
Savings
~20 kW
24 20 kW
4 kW
Annual Savings
=
=
=
=
Investment
Nil
Payback period
Immediate
=
=
=
1300 X 2 X 28 W
72.9 kW
Say 73 kW
Proposed Scenario
It is recommended to replace these T5 lamps with 1X20 W LEDs.
Power consumption of LEDs
=
=
1300 X 20 W
26 KW
Savings
=
=
73-26 kW
47 kW
=
=
=
=
Payback period
(Investment) X 12 months
(Savings)
=
11 months
=
=
80 X 18 W
1.44 kW
Proposed Scenario
It is recommended to replace these CFL lamps with 1X9 W LEDs.
80 X 9 W
Savings in kW
1.44 0.72 kW
Annual Savings in Rs
=
=
0.72 kW X 18 hrs/day
X 365 days X Rs. 5.3/kWh
Rs. 25,000/-
=
=
Investment X 12 Months
Investment
=
=
=
Payback period
0.72 kW
0.72 KW
Savings
=
=
=
=
=
Proposed Scenario
It is recommended to replace the 4 X 14 W CFLs and 2 X 18 W CFLs with 30 W
LEDs and 2 X 9 W LEDs respectively.
Savings in KW
=
=
92.88 kW
92 kW X 3600 hrs
X Rs. 5.3/kWh
=
=
Rs. 17,55,360
Rs. 17.5 Lakhs
Investment X 12 Months
Annual Savings in Rs
Payback period
Savings
=
Rs.17.5 Lakhs`
Confederation of Indian Industry
10 months