Upgrading of Ammonia

Refrigeration Plant for

NCS Cold Stores
AGENDA

• Overview

• Energy Service Company Profile

• Project Key Milestones

• Phase 1 – Preliminary Assessment

• Phase 2 – Detailed Assessment

• Phase 3 – Project Implementation

• Phase 4 – Measurement & Verification

• Lessons Learned

• Opportunities for Further Improvement

OVERVIEW

• NCS Cold Stores is a wholly owned subsidiary of QAF Ltd provides cold storage and
warehousing solutions to the food and marine products market through its Jurong
facility, which has 26 cold rooms and storage area totalling 50,000 cubic metres.

• The cold rooms were served by a centralised ammonia refrigeration plant, with a
two-stage compression system.

• As part of the company’s initiative to explore use of energy efficient equipment

and technology as part of upgrading exercise, NCS Cold Stores engaged an energy
consultant to assist facility manager in identification and development of energy
retrofitting projects.
ENERGY SERVICE COMPANY PROFILE

• G-Energy Global is an accredited Energy Service Company (ESCO) with 4 Qualified

Energy Services Specialists (out of 27), dedicated to the provision of energy
efficient services such as:

– Energy assessments

– Design and management of energy efficiency projects

– Performance guarantee contracting

– Remote energy monitoring

PROJECT KEY MILESTONES

Phase 3
• Application for
Phase 1 GREET scheme
• Preliminary • Development of
assessment M&V plan
• Application for • Project
EASe scheme implementation

Phase 2 Phase 4
• Detailed • Measurement &
assessment verification
• Data analysis and • Continuous
conceptual monitoring
recommendations
PHASE 1 – PRELIMINARY ASSESSMENT

• A preliminary energy assessment was conducted in Nov 2008 with the following
key objectives:

– To understand the energy consumption distribution of the plant.

– To identify areas for opportunities in energy reduction.

• Key observations include:

– Largest consumption of energy by ammonia refrigeration plant

• Impact of any energy conservation measures in this area would be most

significant.

– Opportunity for energy reduction through upgrading to energy efficient

equipment.
PHASE 1 – PRELIMINARY ASSESSMENT
PHASE 1 – PRELIMINARY ASSESSMENT

• Based on findings and recommendations in

the preliminary energy assessment,
application to NEA was made under the
Energy Efficiency Improvement Assistance
(EASe) scheme:

– Up to 50% of cost of follow up detailed

energy assessment may be funded.

– Serves as an incentive to encourage

companies towards detailed energy
assessments and energy efficiency
retrofits.
PHASE 2 – DETAILED ASSESSMENT

• Upon approval of EASe, a detailed energy assessment was carried out to ascertain
the observations and findings made in the preliminary assessment.

• Key objectives achieved by the detailed energy assessment include:

– Measurement of actual power consumption and profile by the ammonia

refrigeration plant.

– Identification that the existing compressors had de-rated capacities that are
insufficient to support the design conditions.
PHASE 2 – DETAILED ASSESSMENT

Avg 38 °C

Avg 10 °C

Design -10 °C
PHASE 2 – DETAILED ASSESSMENT

• Conceptual recommendations proposed to client include:

– Upgrading of ammonia compressors to suit present requirements / load and

to take advantage of latest technological improvements.

– Upsizing of evaporative condensers to enhance effectiveness of heat rejection.

– Use of variable speed drive to regulate fan speed of evaporative condensers

during cooler ambient temperatures.
PHASE 3 – PROJECT IMPLEMENTATION

• With the conceptual recommendations put forward in the detailed assessment, an

application was made for the Grant for Energy Efficient Technologies (GREET)
scheme for co-funding of the project costs.

• Various discussions were carried out to go over the details of the energy retrofit,
with key emphasis placed upon the approach for the measurement and
verification of energy savings.

• Establishment of key performance indicators and baseline allow for the

monitoring, measurement and maintenance of operations to achieve the targeted
energy savings.
PHASE 4 – MEASUREMENT & VERIFICATION

• Key challenges include identification of suitable locations for flow measurement.

PHASE 4 – MEASUREMENT & VERIFICATION

May not be full

bore flow

U-bend not
suitable for flow
measurement
PHASE 4 – MEASUREMENT & VERIFICATION

Proposed location
PHASE 4 – MEASUREMENT & VERIFICATION
PHASE 4 – MEASUREMENT & VERIFICATION
PHASE 4 – MEASUREMENT & VERIFICATION
PHASE 4 – MEASUREMENT & VERIFICATION

• Key data were used to quantified refrigeration load and COP:

– Liquid flow

– Suction/discharge pressures (to cross reference with pressure-enthalpy charts)

– Power of compressors and evaporative condenser fans

• Savings of 21% in COP were achieved which equates to an estimated 700 MWh
savings ($150,000) in annual energy consumption and costs.

• Measurement & verification approach in line with ASHRAE Guideline 14 to achieve

consistency for monitoring and maintenance of savings.
LESSONS LEARNED

• Consultations with facility managers and engineers are KEY steps:

– To understand the systems audited and operational behavior.

– To determine the operating requirements of the facility.

• Achieving energy savings through retrofit requires high level of commitment from
top management to field engineers:

– Commitment to invest in feasibility studies

– Commitment to invest in energy efficient technologies

– Commitment to measure and monitor performance.

OPPORTUNITIES FOR FURTHER IMPROVEMENT

• Improving insulation of cold storage areas.

• Reduction of infiltration through open doors and delivery bays.

– Change in occupational behavior required.

– Operation of coolers to pressurize anterooms.

• Upgrading of lighting to energy efficient lighting:

– Reduction in refrigeration load in additional to direct savings of electrical

energy.

• Incorporate variable speed drives to evaporators for part load control.

Thank you
for creating a Clean &
Green future with us