Chiller Plant Optimization and data driven continuous performance improvement without the replacement of equipment

at

HP, Depot Road

C.V. KumarCOOBBP

Kim Leng

HP

Energy and Sustainability Program Lead, APJ Region

ABOUT BBP• Singapore based data driven energy optimization

solution provider active in Singapore, China, Malaysia, Thailand, Taiwan, Indonesia, Philippines and India with focus on Industrial facilities.

• BBP’s Patent pending optimization algorithm adds a layer of intelligence to existing central chiller plants reducing the energy consumption by 10%-35% leading to date:

q S$100,000 to S$2,000,000 in annual savings per plant

q Cumulative Savings overs 80 million kWh/Year

• Big Data Analytics help BBP in extracting unique insights for each building and act on the insight

• BBP offers its solution without any upfront cost to its customers

ABOUT BBP

• 30 Mn kWh saved annually and projects over 50 Mn kWh annual savings are in implementation phase

• 15,000 Tons of CO2

avoided annually• S$100,000 to

S$2,000,000 in annual savings per plant

• 2017 NEA award winner for RWS project

• 2017 IFMA technology provider of the year

• 2016 Frost & Sullivan Energy Management Solution Entrepreneurial company of the year

• Accredited ESCo by National Environmental Agency

• Accredited EPC contractor and ESD company by SGBC• Infocomm Media Development Authority (IMDA) Accredited for promising Singaporean Technology

Company

Retail Office Industry Hospitality

The only company in Singapore with accreditation for its technology as well as Energy Management Capabilities

BBP system has been used by leaders in commercial and industrial sectors

61

Building Owner : Philips Singapore Pte Ltd

Facility Management: Philips Singapore Pte Ltd

ESD / Green Consultant: Barghest Building Performance Pte Ltd

Lumileds Singapore(Existing Non-Residential Building)

PLATINUM

GREEN MARK AWARD FOR BUILDINGS

• Estimated energy savings: 3,510,562 kWh/yr ; Estimated water savings: 290,026 m3/yr.

• Targeted chiller plant system efficiency of 0.641 kW/ton

• LED lights installed in production plant and office space achieved 40% improvement in Lighting Power budget compared to code.

• Introduction of Water Recycling Plant (recycling of AHU Condensate Water, Production Waste water & RO Reject water) resulted in water savings of 290,026 m3/year.

• Smart meters are installed to capture the daily water consumption and linked to BMS as well as to PUB for monitoring purposes.

• Recycling facilities are available to collect, monitor and control flow of various recyclable materials.

• Green guide and various awareness programs are conducted through EHS website, Training courses and notifications.

BBP addresses key challenge of making existing systems green• New buildings/Plants have to meet Environmental Standards as per regulation

• No regulatory requirement for Existing Buildings/Plants- Not all owners can afford to replace equipment with high payback.

• BBP assess the plant for both optimisation and replacement and use step wise approach to improve plant efficiency

1. Optimise existing plants to its best performance by optimisation.

2. Consider replacing equipment if it makes economical sense even after optimisation or is operationally necessary:

• Initial design efficiency is poor

• Physical condition of equipment is poor

• Spare parts are obsolete or refrigerants are phasing out

§ BBP provides its solution with no capital outlay and guarantees savings

BBP optimisation process flow

• Detailed energy audit using Patent pending Wireless Energy Audit set and standardized process.

• Financial proposal with various option • No capital outlay• Shared savings• Guaranteed payback and savings• Comprehensive maintenance

Initial Presentation

Energy Audit

Financial proposal Installation

Commissioning and Savings verification

• Installation• Baseline by third party• Commissioning and Savings Verification

Cloud based support and Performance based Asset Management

Advanced Analytics

Chiller Plant Efficiency depends on factors beyond design

• Monitor and Maintain KPI related to maintenance like • Pressure drops at heat

exchangers, strainers etc• Heat Exchangers

approach.• Pump Head.• Calibration of Sensors• Refrigerant charge,

superheat and sub-cooling

• Water Quality parameters

• Intelligent PID Controls• Auto detection of sensor

failure• Fail safe limits.• Dynamic corrections of

setpoint (ex.CW supply temperature w.r.t. weather and load demand etc.)

• Remote Realtime monitoring and advanced data analytics

• Modelling of data collected on various conditions

• Data Analytics and finetuning

Design Efficiency (Initial Selection)* Operational Efficiency

Equipment Maintenance (To maintain design efficiency)

Operation and Control (Optimum control and operation)Chiller efficiency and

part load performance

Pump efficiency and Pump curves

Cooling Tower approach and fan efficiency

* Its possible to bring back equipment efficiency close to design condition the overhauling and reconditioning

System or Plant Efficiency

Advanced Analytics can be used for continuous improvement

Vertically integrated data acquisition

Change in control algorithm for lower energy consumptionComplex Insight creation

1 2 3

Fine tuning of algorithm leads to increased savings for clients

Success of Optimization project is dependent on working with the right partner• Proven Track Records in Optimisation

• Expertise and Technology to maintain the efficiency consistently

• Adequate Financial Resources • Optimisation is Resource intensive- Service provider should have In depth

capabilities in:1. Design of ACMV system, Controls and Automation : In-depth knowledge in control systems and

control strategies customised to operational asset2. Addition and Alteration Work: To implement a new system without interruption and

inconvenience when the building is in operation3. Simulation, Selection and in-depth knowledge of Motors, Drives, Chiller, Pumps, CT, AHU/FCU

at component level: To simulate the performance of current operating system and predict thesystem performance and challenges with proposed operating conditions

4. Operation and Maintenance: To address all operation and maintenance issues5. Testing and Commissioning: To properly commission the system- cover air and water balancing,

developing system checklist and KPI to maintain the savings consistently

Typical Track Records of Optimisation and Continuous Commissioning

• 14 Years old chiller Plant and operating below 0.64 since last 4 years

• Chilled Water Supply at 5.8 Deg.C.

• Optimized the plant and installed intelligent control system

• Achieved BCA Green Mark Platinum Certificate.• Originally Chiller was designed at 0.55 KW/RT

Before After Savings

CHILLER KW/RT 0.574 0.523 0.052 9%

CHWP KW/RT 0.138 0.053 0.086 62%

CWP KW/RT 0.104 0.031 0.072 70%

CT KW/RT 0.057 0.034 0.022 39%

Total Plant KW/RT KW/RT 0.873 0.641 0.232 27%

14 year Chillers brought to Green Mark Platinum levels of efficiency and performing better than platinum level efficiency since last 4 years

61

Building Owner : Philips Singapore Pte Ltd

Facility Management: Philips Singapore Pte Ltd

ESD / Green Consultant: Barghest Building Performance Pte Ltd

Lumileds Singapore(Existing Non-Residential Building)

PLATINUM

GREEN MARK AWARD FOR BUILDINGS

• Estimated energy savings: 3,510,562 kWh/yr ; Estimated water savings: 290,026 m3/yr.

• Targeted chiller plant system efficiency of 0.641 kW/ton

• LED lights installed in production plant and office space achieved 40% improvement in Lighting Power budget compared to code.

• Introduction of Water Recycling Plant (recycling of AHU Condensate Water, Production Waste water & RO Reject water) resulted in water savings of 290,026 m3/year.

• Smart meters are installed to capture the daily water consumption and linked to BMS as well as to PUB for monitoring purposes.

• Recycling facilities are available to collect, monitor and control flow of various recyclable materials.

• Green guide and various awareness programs are conducted through EHS website, Training courses and notifications.

Awards and Recognitions for the Philips Lumileds project

Typical Track Records of Optimisation and Continuous Commissioning14 year Chillers brought to Green Mark Platinum levels of efficiency and performing better than platinum level efficiency since last 4 years

Typical Track Records of Optimisation and Continuous Commissioning

Office Building

Results § 37 % improvement from baseline § Contributing to ~800,000 kWh annual energy savings§ Meeting Green Mark Plant Efficiency Requirements.§ Achieved Green Mark Certificate

Typical Track Records of Optimisation and Continuous Commissioning

5 Star Hotel

0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89 0.89

0.84

0.75 0.75 0.76

0.72 0.71 0.72 0.72 0.72 0.73 0.74 0.73 0.73 0.73 0.74 0.74 0.74 0.74 0.73 0.74 0.73 0.72 0.73

FEB-15 MAR-15 APR-15 MAY-15 JUN-15 JUL-15 AUG-15 SEP-15 OCT-15 NOV-15 DEC-15 JAN-16 FEB-16 MAR-16 APR-16 MAY-16 JUN-16 JUL-16 AUG-16 SEP-16 OCT-16 NOV-16 DEC-16

Plant Performance after BBP System Installation

Baseline Plant (KW/RT) Actual Plant (KW/RT)

Results § 19% improvement from baseline § Contributing to ~670,000 Kwh annual energy savings§ Meeting Green Mark Requirements

Typical Track Records of Optimisation and Continuous Commissioning

District Cooling Plant

Ø 36 % improvementØ Contributing savings

around 800,000 perYear

Results § New facility with latest technology and monitoring system§ Already optimised by Energy Services specialist§ Achieved 10 % further improvement§ Contributing to ~5,500,000 Kwh in annual energy savings

ABOUT HP

Our vision is to create technology that makes life better for everyone, everywhere — every person, every organization, and every community

around the globe. This motivates us — inspires us — to do what we do. To make what we make. To invent, and to reinvent. To engineer experiences

that amaze. We won’t stop pushing ahead, because you won’t stop pushing ahead. You’re reinventing how you work. How you play. How you

live. With our technology, you’ll reinvent your world.

This is our calling. This is a new HP.

Keep reinventing.

49.3%

49.3%

1.4%

Sustainability by the Numbers

Energy Efficiency• Replace fluorescent with LED tubes• 1,059 MWh energy savings

3,232 met tons CO2 Emission Equivalent ReductionEnergy Efficiency

• Optimize chiller operations to improve COP

• 2,957 MWh energy savings

Energy Efficiency• Replace old Compressor with new

energy efficient model & ZPL Dryers

• 2,515 MWh energy savings

Energy Efficiency• Replace Electric heater with Heat

Pump• 630 MWh energy savings

Energy Efficiency• EC Motors Replacement for Fan

Filter Unit• 158 MWh energy savings

Renewable Energy• Solar PV System• 298 MWh energy savings

HP Singapore is the first global site to achieve companywide certification of its manufacturing operations to ISO 50001

© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.

Implementing energy management system

HP Chiller Plant Optimisation - Background

• HP Deport road consists of Low Temperature (6.2 Deg. C) and High Temperature (7.5 Deg. C) plants

• Chillers age range from 14 Yrs to 24 Yrs.

• As part of an initiative to reduce the energy consumption HP invited BBP to conduct audit and propose energy savings measures.

• BBP awarded performance contract and implemented Optimisation system in 2016

• Achieved annual energy savings of over 2 GWh.

• Low temperature (LT) chilled water system efficiency improved from 0.89 kW/RT to 0.63 kW/RT (29%)

• High temperature (HT) chilled water system efficiency improved from 0.789 KW/RT to 0.71 KW/RT (10%).

• Further improvement (5%) works on HT plant are in progress

Project Scope• Intelligent control algorithms

• Pump and CT controls• Review minimum and maximum threshold of flow, pressure, temperature

and speed and design algorithms to operate plant at optimum flow, pressure and temperature .

• Operational Safety• Option to choose existing control or optimisation control.• Fail safe conditions.

• Continuous Monitoring and improvement• Daily, monthly and yearly reports.• Dedicated asset management team to monitor remotely and take

immediate corrective action if any required.• Data analytics • Guaranteed performance contract

Challenges faced and addressed

• Resistance from OEM and Maintenance contractors on minimum flow and variable flow requirements etc.

• Educating stake holders and contractors to do timely and proper service

• Addressing perceived risks of equipment malfunction

• Retrofitting a 24h running plant without interruption to existing operation

• Interfacing optimiser and existing system.

• BBP convinced HP on addressing all the operational concerns and given confidence with their proven track records and expertise

Each plant is connected to BBP Central Monitoring System for Monitoring, Reporting and Data Analytics

Low Temperature Plant Efficiency Improvements

High Temperature Plant Efficiency Improvements

HT and LT Plant Efficiency Improvements are driven by improved operational control of auxiliary equipment

LT PLANT

Equipment Efficiency (kW/RT

Before After Savings % Improve

CHILLER 0.559 0.532 0.027 5%CHWP 0.093 0.042 0.051 55%CWP 0.118 0.042 0.076 64%CT 0.119 0.02 0.099 83%Total Plant KW/RT 0.890 0.636 0.253 28%

Equipment Efficiency (kW/RT

Before After Savings % Improve

CHILLER 0.543 0.568 -0.025 -5%CHWP 0.059 0.039 0.02 34%CWP 0.098 0.078 0.02 20%CT 0.089 0.028 0.061 69%Total Plant KW/RT 0.789 0.713 0.076 10%

HT PLANT

Overall Dashboard (HT and LT)

LT Dashboard

Auto Reports

Further Collaboration

• Based on the results achieved HP and BBP are collaborating on following projects that can yield 2 GWh of additional savings:

• HP Tuas Plant-1 Optimisation

• HP Tuas-2 Plant Optimisation

• HP Heat Pump

• HP has also asked BBP to install its optimisation solution at installation stage for its newest plant to ensure and maintaining optimum performance from commissioning stage onwards

• The newest HP plant is operating at system level efficiency of 0.55 KW/RT post BBPs successful implementation.

Conclusion

Ø Optimisation with continuous improvements can contribute to significant savings -For HP, the project lead to 29% savings at LT Plant and 10% improvement at Depot Road Plant

Ø BBP has track record of 10%- 35% efficiency improvement through Retro-commissioning/optimisation across old and new plants.

Ø Savings are ranging from $100,000 to $2,000,000

Ø Solutions are available with no capital outlay

Ø Performance contracting with clear KPI and selection of right partner are important factors for maximising the achieved savings, successful implementation and maintaining efficiency over time.