Category Archives: Energy Audit

How an HVAC Audit Company can help in saving HVAC Project Cost?

An HVAC Energy Audit Company is required to reduce operational expenditure, decline in wear and tear on equipment, longer equipment life all culminating in a  better working environment. To achieve this, we need to conduct an HVAC Audit.

Next, to lighting, HVAC is the largest energy user in a building, so improvements in the HVAC system can significantly lower the total energy bill – by up to 40 percent. HVAC Audit tells about equipment performs and how much energy HVAC system consumes. Once consumption pattern is available, an HVAC Audit Company can compare against upgrade options, get ROI estimates, and make informed decisions.

HVAC Energy Audit
HVAC Energy Audit

Benefits of HVAC Audit

Equipment performance can be greatly improved with an audit e.g. easy things like changing filters on time can save electricity and save an air-handler from premature failure.

Also, HVAC Audit can save Energy in terms of:

  • Adding variable speed drives to chillers and other big load HVAC equipment.
  • Approprratelitly doing sizing of the fans
  • Adjusting controls (changing setpoints due to cyclical seasons) or upgrading them.
  • Optimizing ventilation according to the capacity utilization
  • An HVAC Audit can also help in identifying worn motors, leaky valves, inefficient compressors, ineffective heat exchangers, and inefficiencies in the fuel/energy process
  • Identifying HVAC equipment running less than their optimal efficiency

The building environment is constantly changing: seasonal temperatures, building upgrades, office space use, number of occupants, etc. An audit will quickly identify if your system is updated and tracking to all of these changes.

HVAC Energy Audit
HVAC Energy Audit

When to do an HVAC Audit & by whom?

A routine audit should be done at least once every 12 months by a professional HVAC Audit Company.

However, it is recommended to perform an audit whenever you find inefficiencies on a daily or weekly basis e.g. long boiler runtimes, water loss, steam leaks, high stack temperatures, etc. An HVAC Audit Company will look at these areas, triggering alerts to crucial issues, documenting results, and maintaining useful historical records.

Also, the basic changes to be done quarterly to monitor the energy use of key components such as chillers, boilers, air handlers, etc.; ensuring the correct operation of dampers, condition of filters, and ventilation rates; etc. Also, it is advisable to maintain an inventory of information – equipment age and size, make/model, maintenance schedule, dates of any upgrades as a ready input for an HVAC Energy Audit Company.

MG Cooling Solutions is a complete HAVC Solution provider in India contributing to various HVAC related issues including HVAC Audit to save energy cost for its clients.

 

How to reduce Warehouse Energy Cost & Save Energy ?

With the ever-growing presence of Warehouses in India, it becomes imperative to reduce Warehouse Energy Cost. India is going to become a digital economy soon.  In the last decade, we have seen various e-commerce companies marking their presence in the Indian market. As we know, all E-commerce companies need warehouses which need to be backed up warehouses to store and protect the inventory before it reaches its destination.

Warehouse Energy Cost
Warehouse Energy Cost

Since warehouses consume a  lot of space, it becomes imperative to reduce energy costs to save money. Below mentioned are some tips to reduce Warehouse Energy Cost.

Warehouses Energy Audit

An energy audit will help you better understand your energy usage and determine where your facility can go green and save money. An Energy Audit Company can help in making a detailed analysis of all the plant and machinery installed in the warehouses to reduce Warehouse Energy Costs

Lightning

Lightning, being an electrical item is a part of Energy Audit but it must be given more significance as most of the warehouses run 24 by 7 and lightning are always operational. By simply replacing your lighting with energy efficient products and controls, you can reduce energy consumption up to 50 percent as well as eliminate the risk of mercury contaminants in a very short period of time

Evaluate your motors and drivers

Electric motors are responsible for almost 70 percent of all energy consumed in industrial applications. This 70 percent holds a considerable saving potential that is just waiting to be realized. Hence it makes sense to replace existing motors with energy efficient motors. One more addition is to save even more by adding variable frequency drive systems to the motors which can contribute to some 30 percent energy savings with a seven-month return on investment.

HVAC ( Heating & Cooling Costs)

HVAC ( Heating, Ventilation & Air Conditioning) is vital for any warehouse to function. Hence, one must think about hiring the right HVAC Company in India to make sure that the HVAC system is not over designed which will help in reducing Warehouse Energy Cost. Also, an HVAC Audit can help in knowing for any kind of deficiency in the system.

Hence, Warehouse Companies must think about all such factors to make sure that they can reduce Warehouse Energy Cost. MG Cooling Solutions, an HVAC Company In India working in the same direction of saving warehouse Energy Costs through precise HVAC Consultancy, Design & Audit.

Instruments used in energy auditing

Energy audit is a technical tasks which involves lots of calculations and precise work. To make the audit result more precise and audit, we need highly calibrated instruments which give readings which are very accurate.

Anemometer
Anemometer
Infra Red Thermometer
Infra Red Thermometer
Light meter
Light meter
Ultrasonic Flowmeter
Ultrasonic Flowmeter

It is always advisable to use all the gadgets and instruments form some high end manufacturers to make sure that audit goes in right direction. Here, we present some of the instruments which are required for any audit to progress in right direction.

  • Anemometers
  • Combustion Analyzers
  • Ultrasonic Flow Meters
  • Infrared Thermometer-Used for measuring temperatures from a distance using infrared technology.
  • Combustion Gas Monitoring and Control Instruments
  • Light meters(luminosity )
  • Multi meters(volts,amperes and ohms)
  • Watt Meters
  • Power factor Meters
  • Ultra sonic Stream Trap Tester
  • Stroboscope Non-contact Tachometer
  • Non-contact Infrared Thermometer
  • Contact Thermometer
  • pH meters-To check acidity/alkanity of water or any other liquid.
  • Steam trap Monitor
  • Fuel Gas Analyzer
  • Temperature Indicator
  • Thermal Insulation Scanner
  • Conductivity meter
  • Thermo hygrometer
  • U-tube manometer
  • Digital manometer
  • Visgauge
  • Demand Analyzer
  • Power Analyzer
  • Harmonic Analyzer
  • Luxmeter
  • Frequency meter
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Energy Audit for AHU-MGCS Energy Audit Company

CASE STUDY: 3 PERFORMANCE OF AHU

 

Technical Details of AHU

  • Double skinned type AHU with PUF (25 mm thick) are provided with EFF1 level motors.
  • Blower with paddle blade impeller are provided.
  • The belts are V-Belt.
  • Chilled water coil of copper tube with finned aluminum fins provided.
  • Chiller coils with 6 rows with 12 fins per inch spacing provided.
  • The fan is so designed with outlet velocity restriction upto maximum 10 m/sec. 50mm thick air filter with 3 ply HDPE with 2 layers of aluminum provided.
  • The ducts are of galvanized sheet with suitable insulation and support.

Layout Details

  • There are 12 nos of Air handling unit in the premises.
  • Motors are operated through Star-Delta and DOL starter.
  • There is no controlling of chilling water or other sensor to control AHU.

SCHEMATIC DRAWING OF AHU

AHU Schematic Drawing for Energy Audit
AHU Schematic Drawing for Energy Audit

PERFORMANCE OF AHU

Energy Audit data for AHU
Energy Audit data for AHU

TECHNICAL EVALUATION AND RECOMMENDATIONS

 

  • From Above Table, 5 out 9 AHU Specific energy consumption kW/TR is higher than design.
  • RPM of fan also has been derived through formula as it connected through V-Belt.
  • Through static pressure it can conclude there is no obstacles in return air path, G-5 & G-6 considerably on higher side.
  • Replacement of V-Belt with Flat-Belt as per below mentioned cons and pros

Disadvantage of V-Belt:

There is a power transmission loss of about 5-7%, when V-Belts “WEDGE IN” and “WEDGE OUT” of the grooved pulley.

Advantage of running in Flat Belt:

  1. Prevents elongation due to moisture absorption.
  2. Ensure Better Grip of Pulley.
  3. Energy Saving of at least 5-7%.

Energy Saving Recommendation:

Conversion of V-Belt to Flat belt in all AHU’s between Motor and Fan.

Result of the outcome:

Energy saving of at least by 5-7%

Proposed Electricity Saving

Saving Calculation:

Total Consumption in AHU = 63.05 KW

Energy Saving @ 7%              = 4.413 KW

Energy saving per annum     = 4.413 X 10 X 240 ( 10 hours ,240 days of working)

= 10592.4 kWh

Monetary Saving                   = Rs 1.18,105.2/-

Investment                             = 50,000/-

Payback                                  = 5 Months

Annual GHG Mitigation 8.78 ton of CO2

Please go ahead and get your electrical, thermal devices audited now to save on money. 

http://www.mgcs.net.in/hvac_energy_audit.php

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Energy Audit of Cooling Tower

CASE STUDY 2: AUDIT of cooling tower

Sample case study for audit of cooling tower. With our precise and scientific instruments, we have analyzed below mentioned data for two number of cooling towers installed at client side.

Performance of Cooling Tower   
SN. Description Units CT-1(MOB) CT-2 (MOB)
1 Cooling water flow m3/hr 180.00 202.00
2 CT Fan Flow m3/hr Fan Less CT
3 CT water inlet temp °C 29.00 30.00
4 CT water outlet temp °C 27.00 28.00
5 Dry bulb temp. °C 29.00 29.00
6 Wet bulb temp. °C 26.00 26.00
7 CT Range °C 2.00 2.00
(water i/l temp.-water o/l temp.)
8 CT Approach °C 1.00 2.00
(water o/l temp-wet bulb temp.)
9 Evaporation losses 0.31 0.31
10 Effectiveness % 67 50

 

Technical Evaluation & Findings:

  • This is of Natural Air cooling Tower with 6 rows and each row has 14 nozzles. In cooling tower-1 only 5 rows are operation and in other cooling tower -2 all 5 rows are in operation. Height of the cooling Tower is 4.2 m
  • No chemical additives are added to maintain the TDS.
  • Chiller condensing water is been cooled here, the main criteria is outlet temperature which should be 28°C  but as the cooling tower completely covered by building it will affect cooling water outlet temperature.
  • Proposed system: The cooling tower need to shift to terrace where there is no obstacles so the air will flow from down wards and cooling water temperature will be below 28°C.

 

 

Energy audit for chiller plant

MGCS-Energy audit company

    Case Study- Performance of Chiller:

Existing Conditions-Two chillers are installed at one of our client site with the operating principle of vapor compression.
Mostly two chillers are in running condition due to climatic condition. Cooling tower is Natural air cooling.

energy audit for chiller plant
energy audit for chiller plant

Chiller Details

a) Rated Capacity in TR for Chiller 250 TR
b) Sr. No. of Chiller — SHMM-035670
c) Model No KWF195.12
d) Make of Compressor — YRWDWBT1555A
e) Type of Compressor — Screw Compressor
f) No. of Stages — Single Stage
g) Other Relevant Number Plate Refrigerant 134a, Oil Flooded, RPM of compressor 2950 RPM, Direct Drive type, step less capacity control.

Motor Details

a) Make of Electric Motor — York maxe
b) Sr. No. of Motor — F00580SG03
c) Connected Motor Kw — 170 kW
d) Rated RPM — NA rpm
e) Rated Efficiency of Electric Motor 92 %
f) With or Without VFD / Type of Starter Without VFD
g) Type of Transmission in Motor & Comp. Directly Coupled

The performance assessment of the chiller SPC, COP & EER Calculations from Condenser Circulation Data

Measured Data & Analysis Chiller-1
Compressor Speed
Ambient dry bulb temperature — °C 29 29
Ambient wet bulb temperature — °C 26 26
Water Flow rate through condenser, m3/hr 180 202
Cooling Water density kg/cm3 1000 1000
Specific heat of Cooling Water kcal/kg°C 1 1
Water temperature at inlet to Condenser °C 28 30.5
Water temperature at outlet to Condenser °C 33 32.83
Heat Rejected Through Condenser Kcal/hr 900000 470660
Heat Rejected Through Condenser TR 297.619 155.64
Condenser pressure kg/cm2 9.37 9.56
Condenser saturation temperature °C 40.16 40.8
Sub cooling temperature °C -11.3 -15
Power input to motor kW 87 89.00
Likely motor efficiency % 90.6 90.60
Likely drive transmission efficiency % 98 98.00
Estimated Compressor shaft power kW 77.24556 79.02
Coefficient of Performance, COP 12.007 6.138
Energy Efficiency Ratio, EER Btu/h-W 40.945 20.931
Specific power consumption, SPC — kW/TR 0.292 0.572

SPC, COP & EER Calculations from Evaporator Circulation Data
Measured Data & Analysis-CHILLER 2

Compressor Speed — RPM
Ambient dry bulb temperature — °C 29.0 29
Ambient wet bulb temperature — °C 26.0 26
Water Flow Rate through Evaporator m3/hr 292.0 305
Density of Water kg/cm3 1000.0 1000
Specific heat of Water kcal/kg°C 1.0 1
Water temperature at inlet to Evaporator °C 16.4 13.05
Water temperature at outlet to Evaporator °C 14.2 11.7
Refrigeration Effect kcal/hr 642400.0 411750
Refrigeration Effect TR 212.4 136.161
Evaporator pressure kg/cm3 4.07 3.3
Saturation temperature °C 11 15.7
Power input to motor kW 87.00 89.00
Likely motor efficiency % 90.60 90.60
Likely drive transmission efficiency % 98.00 98.00
Estimated Compressor shaft power kW 77.25 79.02
Coefficient of Performance, COP 8.571 5.370
Energy Efficiency Ratio, EER Btu/h-W 29.226 18.311
Specific power consumption, SPC kW/TR 0.410 0.654
Evaporator to Condenser TR Ratio kW/TR 0.714 0.875

Technical Evaluation

OUTCOME 1: Lift is difference between the evaporator pressure and condenser pressure.Greater the pressure, more energy for given load.
Lift for Chiller 1 is 5.3
Lift for Chiller 2 is 6.26

It shows that condenser in chiller 2 condensers is fouled as it requires more energy to do the work.

OUTCOME 2: Condenser approach should be between 0-2 (Liquid refringent temperature – Condenser outlet temperature)
Condenser approach for Chiller-1 1.44
Condenser approach for Chiller-2: 4.47
so it can conclude that condenser in chiller-2 is fouled.

OUTCOME 3: Most chillers are designed with max condenser inlet temperature of 28°C. if it exceeds efficiency of chiller will decrease by 2% for every one degree in raise.

OUTCOME 4: Condenser Inlet temperature for Chiller-1: 28°C and 30.5°. It can be either instrument problem or cooling tower problem.

OUTCOME 5: Evaporator approach for chiller -1 & 2 is 3.22 and 4 respectively. As design data is not available auditors can’t command on it.

Energy Saving Recommendation:
Chiller-2 condenser need to cleaned.
Result of the outcome:
Chiller-2 efficiency will improve and approach too.
Present Scenario: Condenser approach=4.47
After technical recommendation: Condenser approach = < 2
Proposed Energy/Electricity Saving
Saving Calculation:
Consumption = 87 kW
Energy Saving @ improving 4% of efficiency = 3.48 kW
Energy saving per annum = 3.48 X10 X 240 ( 10 hours ,240 days of working)
= 8352 kWh
Monetary Saving = Rs 93125/-
Expected Pay back = Immediate

This way, we helped our client in saving money by taking the corrective action through our detailed auditing for the chiller plants.

Note: The above information is only for knowledge sharing and MGCS has its sole right and proprietorship of above technical data.

Aspects of Energy Audit for HVAC Systems

Technical analysis of energy audit for some of the HVAC System components:

1.1 Chillers

1. Measuring all the operating parameters such as water flow inlet &out water temperatures, gas suctions &discharge pressure, Power Consumption etc.
2. Calculation of operating Input KW per TR (IKW I TR) of Chiller(s) for each chiller.

1.2 Pumps

1. Measuring all the operating parameter such as water flow, suction &discharge head, power consumption etc.
2. Performance Evaluation of chilled water &Condenser water pumps and compare the same with the design or generally expected efficiency of such pumps.

1.3 Cooling Towers

1. Measurement of various parameters for cooling tower fans, water flow rate, air flow rate, dry bulb temperature (DBT) wet bulb temperature (WBT) sump temperature, relative humidity etc.
2. Evaluation of cooling tower performance (Range, approach, and effectiveness).

1.4 Air Handling Units

1. Measurement of airflow, Relative Humidity(RH), Supply air temperature (Tsa), Return air temperature (Tra), Chilled Water Inlet and outlet temperature i.e. Tin, Tout through cooling coil and energy consumption of Air Handling Units (AHUs).
2. Examination of Air Handling Units for air delivery capacity, capacity utilization, temperature pattern, pressure drop and operational pattern with respect to time.
3. Calculation of actual tonnage of AHUs and Measurement of operating zone Temperatures under each unit.