Final Report

On
Replace Vapor Compression Chiller Item # CSD-KM29-T
With Vapor Absorption Type Chiller
at East Compressor Bldg at
Air & Water Plant
ABQAIQ PLANTS
SAER-6311
By

KHALID A. MULHIM / ADEL AL-HAMID / SALEH AL-ZAHRANI

&
MOHAMMAD R. BAIG / MOHAMMED T. AL-HAJRI
(Field Partner Contributor)

Dhahran
12/13/10

Table of Contents
Table of Contents ................................................................................................................. 2
Executive Summary ............................................................................................................. 3
Background .......................................................................................................................... 5
SiteLocation.....6
Commissioning Period .................................................................................................. 6
Evaluation Methodology ....................................................................................................... 7
Data Collection ..................................................................................................................... 9
Results ................................................................................................................................. 9
Data Exclusions .............................................................................................................9
Discussion ...................................................................................................................10
Analysis Section I ......................................................................................................10
Performance Summary ................................................................................................10
Conclusion ..........................................................................................................................11
Recommendations ..............................................................................................................12
Lessons learnt......12
Appendices .........................................................................................................................13
Appendix I Old Compression Type Chiller Energy Consumption
Appendix II New Absorption Type Chiller Energy Consumption
Appendix III Absorption vs Compression Type Chiller Energy Consumption
Comparisson

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EXECUTIVE SUMMARY
This Technology Item TI # CSD-KM29-T titled Vapor Absorption Chiller was initiated
in 2005 based on the Innovative Idea #26454 by Mohammed R. Baig ID #73629.

The idea was evaluated in collaboration with our field partners Abqaiq Plants
Operations Department (APOD) and SACR Community Services Department
(SACR-CSD), Abqaiq. The absorption Chiller technology was installed as a prototype
on a 100 ton Chiller located in East Compressor Building at Air & Water Plant, Abqaiq
Plants.
This report evaluated TI # CSD-KM29-T titled Vapor Absorption Chiller. The Vapor
Absorption Chiller achieved approximately 90% savings of the overall electrical
energy consumption. As a result, the Vapor Absorption Chiller was recommended to
be added to Saudi Aramcos Best Practice SABP-K-001 Energy Efficient Buildings
as means to conserve electrical energy. Additional highlights of this report include the
following:

The Vapor Absorption Chiller System

Energy conservation is a strategic imperative for Saudi Aramco

Vapor Absorption Chiller System

It is specifically designed to reduce the dependence on electricity and provide

process cooling and air conditioning requirements using low cost energy sources like
low pressure or medium pressure steam from the plant, hot water, exhaust gas from
DG sets, GT, including using fossil fuel like diesel, natural gas. Savings are achieved
on operating & maintenance cost, all thru the operation of the absorption chiller. It is

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an ozone friendly system as it utilizes water as a refrigerant. Operation and

maintenances undertaken with minimum man interface and at a lower cost than
conventional compressor based chillers, since there are minimal moving parts.

Energy conservation is a strategic imperative for Saudi Aramco

The absorption chiller is an emerged technology which was tested in Saudi Aramco
over a period of six (06) months and found that it has the capability to reduce
electrical energy consumption by approximately 90% compared to conventional
Compression Type Chiller without compromising on the reliability of the equipment.

A preliminary desk review evaluation determined that:

The operation of the absorption chiller reduces energy consumption of an air

conditioning system without compromising the conditioned space temperature of
the building.

Silent and no vibration during operation due to absence of compressor and major
moving parts resulting to greater reliability of the equipment.

BACKGROUND
The absorption chiller is a technology specifically designed to reduce electrical
energy consumption of an air conditioning or refrigeration system.

Savings are

achieved through the operation of chiller withstanding the harsh environmental

conditions in Saudi Arabia without penalizing the temperature of the air conditioned
space and without any detrimental effect to the mechanical operation of the system.

The absorption chiller is a proven and reliable technology, which is in use worldwide,
over 100 years and this technology was first invented by Mr. Ferninand De Carre a
French Scientist way back in 1890. Till Date more than 5000 units have been
installed and the absorption technology is used by some of the worlds leading
corporations.

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The idea to adopt the absorption technology in Saudi Aramco was initiated in 2005
based on the Innovative Idea #26454 by Mohammed R. Baig ID #73629.
Consulting Services Department approached two manufacturers Dar Al Riyadh
(Thermax Ltd.India) and Broad Air Conditioning (China) for initial discussions about
the absorption chiller as an energy saving solution for HVAC in April 2005. After initial
meetings with its Field Partners APOD and SACR-CSD it was agreed to pioneer the
absorption chiller as a Technology Item (TI) with Thermax Ltd. through their local
representative Dar Al Riyadh. The chiller type and location was selected inside
Abqaiq Plant as a pilot project to test the subject technology.

Purchase Order was issued by Saudi Aramco in 2007 and the Absorption Chiller was
ready for inspection in 2008. A team of four Saudi Aramco employees (Khalid A.
Mulhim, Mohammed R. Baig, Salih M. Jaza and Mohammad T. Hajri) visited
Thermax Ltd. Factory, India in 2008 to inspect and witness the actual operation and
Factory Acceptance Testing of the Absorption Chiller before shipment.

SITE LOCATION
Existing one hundred tons cooling capacity Water Cooled Reciprocating Type Chiller
at East Compressor Building at Air and Water Plant in Abqaiq plants was selected to
be replaced with the absorption chiller technology. Since the low pressure waste
steam (60PSIG) was readily available at this location, proposed chiller was selected
to be driven by LP steam.

COMMISSIONING SCHEDULE
The commissioning of the chiller was carried out over a period of seven days and the
following activities were carried out by Thermax commissioning engineer under the
supervision of the APOD and SACR-CSD team.

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1) During the commissioning of this chiller the team noticed that the chiller is not
getting enough vacuum inside the chiller. The vacuum (or purging) pump was
inspected and cleaned to make sure it is functioning properly.
2) After the vacuum pump has been inspected and cleaned, still the chiller was not
getting enough vacuum and decided to conduct leak testing on the tubes. Leak
was found in the Generator section tubes wherein the tubes were corroded. The
entire tubes of the Generator section were replaced.
3) Thermax also conducted Eddy Current Testing in the Absorber, Condenser and
Evaporator section to ensure the integrity of the other coils. Some of the tubes in
the Evaporator and Absorber were traced indicating wall thickness reduction and
also replaced.
4) The chiller was blanketed with positive nitrogen pressure of 1.0kg/sq.cm in all the
shells for 24 hours, no drop in pressure indicating good perfect condition of the
chiller.
5) Vacuuming of chiller, holding the chiller at that vacuum for 24 hours at 20mmHg
pressure condition was undertaken to confirm the leak tightness of the machine.
6) Then Lithium bromide and demineralized water were charged into the machine
under vacuum condition.
7) Thermax commissioning engineer checked the safety settings of the chiller and
wiring of safety interlocks.
8) The de-superheating station, pressure regulating valve, steam lines and
condensate lines were inspected to ensure low pressure dry saturated steam
going into the chiller.
9) The adjustment for chilled water and condenser water flow was done by slowly
giving the heat input to the chiller.
10) The chiller was then tuned to the parameters required as per site conditions.
11) Checking of setting of safeties and simulation of trips was done.
12) The machine was handed over to put in operation.

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EVALUATION METHODOLOGY
This TI was evaluated in collaboration with our field partners APOD and SACR-CSD,
Abqaiq. The absorption technology was installed as a prototype on a 100 ton Chiller
located in East Compressor Building at Air & Water Plant, Abqaiq Plants.
Evaluation was carried out over six month period, (recorded data is available from 07
April 2010 to 30 October 2010, attached the same in Appendix II). During this period
a SACR-CSD Engineer visited the site regularly to monitor the operating status of the
new Absorption Chiller.

This prototype resulted in annual savings of approximately 247,900 kWh or an

energy cost of $10,577. The following chart indicates the savings on energy gained,
when operating the absorption chiller as against the compression based
reciprocating chiller:

Operating Cost Analysis comparison between Vapor Absorption and Vapor

Compression Chiller.
Water cooled
Absorption system
by Steam

Water cooled
Conventional
System by
Electricity

100
Electricity & Steam

100
Electricity

SR/kg
SR/KW
SR/m
Hours
Kg /hr

0
0.16
4
4320
793

0
0.16
4
4320
0

KW/hr
KW/hr

3.25
5

100
5

DESCRIPTION
Cooling capacity
Operating system
Utilities tariffs:
a- Low pressure or Waste Steam
b- Electricity
c- Water
Six months Operating period
Steam consumption
Electricity consumption
a-Machine
b-Cooling Tower fan
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c-Cooling Towers pumps

Total Electricity consumption
Energy cost
a- Electricity

KW/hr
KW/hr

15
23.25

12
117

SR/hr

3.72

18.72

Total energy cost

SR/hr

3.72

18.72

Cooling tower water consumption

Water cost
Hourly operating cost
Half yearly operating Cost

m3/hr
SR/hr
SR
SR

1
4
7.72
33350.4

0.8
3.2
21.92
94694.4

Total Half yearly operating cost

SR

33350.4

94694.4

Half yearly operation cost difference when using

Steam fired absorption system

SR

61344

80%

65%

Saving In Electrical Power against Water Cooled

electrical chiller
Saving In Annual Operating cost against Water
Cooled electrical chiller

DATA COLLECTION
Throughout the period of the assessment the absorption chiller performance was
monitored. Please refer Appendix II

All cost calculations contained within this report used an average kWh rate of SR
0.16 or approximately $0.05 USD per kWh as per the recommendation of Saudi
Aramco Consulting Service Department / Energy System Unit.

RESULTS
To determine the energy saving performance of the absorption chiller in this
assessment it is necessary to compare data in different time periods with the

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absorption chiller on and off. In reality many other factors impact the performance
and energy consumption of the chiller; these are as follows:
1) Lower cooling water temperature / ambient temperature.
2) Super heated steam / high pressure steam
3) Variable cooling water flow
4) Storage/ long term/ short term, shut down.

DATA EXCLUSION
Examination of the kWh data set from the energy loggers highlights some of the data
that, for the purposes of performance evaluation, has been excluded from the saving
calculations contained within this report.

1) Chiller Failure / Logger Failure

2) Erroneous data
Complete data summary sheet in appendix

DISCUSSION
Energy usage recorded over a period of time obtained from the previous log of the
Old Compression Chiller and the data obtained from the data log from the New Vapor
Absorption Chiller indicates an approximate savings of 90% on energy.

PERFORMANCE SUMMARY
During the assessment period the SACR-CSD engineer visited the site regularly to
monitor the chiller and observed the following things:
a. The machine was working satisfactorily and doesnt affect the performance of
the chiller when operating at high ambient conditions, variations in
temperatures and humidity.
b. It can handle continuous operation throughout the day without much manual
intervention.
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c. No vibrations and low sound levels were observed.

d. The

chiller performance
temperatures.

was

satisfactory

at

varying

cooling

water

CONCLUSION
From this assessment we can conclude the following:
1)

Absorption

chiller

having

minimal

moving

parts

is

reliable

technology/chiller system.
2)

Operation being complete automated using its dedicated PLC, The controls
of the Chiller can be configured to be monitored in the DCS, thus reducing
man intervention.

3)

Energy lost, by condensing or venting of low or medium pressure steam

can be recovered and used for generating Chilled water, using a steam
fired Absorption Chiller.

4)

Substantial financial and environmental benefits can be achieved in

reducing power consumption of the chillers, thus reducing the amount of
CO2 gases released into the atmosphere as a byproduct of fossil fuel
burning to generate power.

5)

Differential Cost of the Capital investment, incurred for Installing an

Absorption Chiller system, as against a conventional system, can be
recovered within 1-2 years, depending on the source of energy, as
indicated in the Articles Discussions (Analysis Section) and Performance
summary.

6)

Waste Energy from Exhaust Gases, of the Turbines or Gensets or other

Industrial Exhaust can be recovered and generate Chilled water, thus
waste energy, can be utilized to the maximum extent, reducing
dependence on grid supply, for air conditioning and process cooling.

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7)

Oil or Gas Fired Absorption Chillers are also available for Industrial and
Commercial Usage, in the event of non-availability of Low or Medium
pressure Steam or Exhaust Gas.

RECOMMENDATIONS
In light of the results from this assessment it is recommend to:
1)

Include the Absorption Chiller in Saudi Aramcos Best Practice SABP-K001 Energy Efficient Buildings to decrease electrical energy consumption
for 100 tons and above.

2)

The chiller that was installed was Single Stage Absorption Chiller and in
the next project, it should be Triple Stage to evaluate the difference in
performance and energy savings.

3)

Continuous research for enhancing the saving potential of Absorption

Chiller.

4)

Use of data loggers with built in memory not less than 50 megabyte to
monitor power consumption.

5)

Area classification and protection classifications to be included based on

the application area.

LESSONS LEARNT
1)

Shipping

Care

Packaging

&

Nitrogen

holding.

During

Shipping/transportation of the Absorption Chiller, from the manufacturing

factory, proper vacuum packing methods needs to be followed, along with
sufficient quantity of Silica Gel pads positioned in the Packing, to avoid
ingress of Moisture, which is one of the main constituent of corrosion.

If Factory Performance Tests are a necessity, proper care should be taken

to remove the Chemicals (Libr) from the chiller, to the maximum content,

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with immediate charging of Nitrogen, maintaining Positive pressure, at all

times, all through the Shipping and transportation, to avoid corrosion of
internal parts.
2)

Storage

If

storage

of

the

Chiller

is

required,

before

actual

installing/erection and commissioning, following precautions, need to be

followed:
a) It should be covered until its installation.
b) It is recommended to keep the chiller indoors during this period to
prevent any damage to it.
c) Nitrogen should not be removed from the chiller unit.
d) All the accessories supplied along with the unit should be kept in the
same place.
If the Absorption Chiller has to be stored for non-usage, after a short or
long term of usage for more than one month, following precautions need to
followed,
a) Charge nitrogen gas up to 0.3 kg/cm2 pressure condition.
b) Drain Cooling water from the circuit, open the headers and keep the
tubes in dry condition.
c) Drain the condensate from the steam lines.
d) Monitor the nitrogen pressure for every 15 days.
3)

Steam Quality - Type of Absorption chillers are based on the availability of

Dry Saturated Low pressure or Medium pressure steam. Dry Saturated,
non-contaminated (if possible) steam is a must for trouble free operation of
the Steam Fired Absorption Chiller. Hence Preliminary investigation must
be carried out, to find out the available pressure and the type of available
steam - Dry Saturated or Super-Heated steam. If super-heated steam is
available, suitable De-Superheating station to be included in the scope, to
meet the design condition.

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4)

Steam Pressure - Type of Absorption chillers are based on the availability

of Dry Saturated Low pressure or Medium pressure steam. If the available
steam pressure, does not match the required design pressure, proper
Pressure reducing station to be included in the initial scope. This pressure
reducing station can be coupled with the De-Super Heating station, if
required.

5)

Provision for condensate system A steam fired Chiller, uses the latent
heat, from Steam, in the in-built generator, before discharging it, as Hot
Condensate. This energy filled condensate, should be recovered, by
means of a condensate recovery system, comprising of receiving tank,
transfer pumps, controls, piping and fittings, for discharge in the
condensate return system of the plant.

6)

By pass provision for lower condenser water temperature during winter.

Lower

Condenser

Water

Temperatures,

beyond

the

designed

temperatures would lead to the Heat of Dilution, being reduced/taken away

at a considerably faster rate, leading to Crystallization. Thus suitable
Bypass, provision, based on the Temperature Control of Condenser Water
Inlet condition, to be provided.
7)

Condenser Water Inlet Shut-Off In the event that no dedicated

Condenser water pump available for the chiller or a common Pumping
station is being used, an Auto Shut Valve, should be installed, at the inlet
of the Condenser Water connection of the Absorption Chiller. This is
required to avoid continuous reduction of the Heat of Dilution in the
Absorber and Condenser, leading to Crystallization of the Chiller.

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Appendices
Appendix I

Appendix II

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