4. 1 SCIENCE AND TECHNOLGY COMPLEX 4.1.1.

Organizational Background Science and Technology Complex consists of Faculty of Civil Engineering, Faculty of Mechanical Engineering, Faculty of Electrical Engineering, Faculty of Chemical Engineering, Faculty of Medicine, libraries, computer labs, labs and server room. The complex is using District Cooling System to cool down the building to meet occupants comfort. The complex consists of 5 blocks and 2 towers with height of 20 levels each.

4.1.2. Design System Overview:

Figure : TES in S&T Complex

TABLE 3: District Cooling Design Chiller Installed 2 x 1800 RT Base Mode 2 x 1250 RT Ice Mode Thermal Storage Capacity Building Cooling Load Requirement 45 x 240 RTh Ice Cell Block 1 550 RT Block 2 580 RT Block 3 380 RT Block 4 850 RT Block 5 660 RT Tower 1 290 RT Tower 2 290 RT MaxCooling Demand 3600RT

At night (10pm-8am), Chiller absorb heat from water in Ice-cell. During the day, (8am-11pm), ice in ice-cell absorb heat from the building, Condenser in the chiller is cooled by cooling towers.

1. Chiller

Figure : Chiller Specification Made: Dunham-bush Model: WCOX128B-128B

Compressor Type: Horizontal screw Power input (kW) : 1227 Function to make ice and cool the buildings Capacity: 1800Rt (normal) & 1250 Rt (ice) Q uantity: 2 Chillers with 4 Compressors D esign Temp: 47.5 / 39 F (normal) 28 / 22 F (ice)

Figure : Chiller System Basic system chiller for operation: a. b. c. d. e. f. Chillers Pumps Heat Exchangers Condenser Water Pumps (CWP) Secondary Chilled Water Pumps (SCHWP) Cooling Tower There are 4 chillers for the thermal energy storage system. The chillers tagged as Chiller 1A, 1B, 2A and 2B. There are 4 heat exchangers to transfer

heat and reduce the pumps work. The chillers and heat exchangers are use alternately. One will standby and the other will operate. On the next schedule, different components will standby and operate. It will alternate every month. Typical Chiller Operation In order to start a chiller the following condition must be met a. b. c. d. e. f. g. h. i. Chilled water pump running Chilled water flow switch made Control power switch and compressor switch on Circuit breaker on All safety condition satisfied Reset pressed on microcomputer keypad The compressor has not started within the last 20 minutes Leaving temperature 2F or more above setpoint Oil sump temperature is greater than 70F

The microcomputer will start the oil pump first. If capacity indicator is below 8% and a minimum of 27 psi oil pressure is established, the microcomputer starts the compressor motor 5 seconds later. Oil pressure and discharge are then monitored to ensure that a different of at least 26 psi is maintained. When the compressor starts, the microcomputer monitors leaving water temperature, ramp schedule and load limiting to control load and unload solenoids. The refrigerant level sensors and discharge temperature are used to control the refrigerant modulating motor. When minimum compressor capacity exceeds system load and water temperature fails below set point, the compressor and oil pump will shut down.

2. Cooling Tower

Figure : Cooling Tower Cooling towers are heat removal devices used to transfer process waste heat to the atmosphere. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or rely solely on air to cool the working fluid to near the drybulb air temperature. Common applications include cooling the circulating water used in oil refineries, chemical plants, power stations and building cooling.

Figure : Cooling Tower System Cooling Tower Specification Brand: Polacel Model: sq 2500T

Type: induce draft cross flow Capacity(Refrigeration tons, Rt): 2500 Water flow: 5000 IGPM(Imperial Gallon per Minutes) Water temp(F): in(97) & out(87) Fan power: [7.5 kW x 8]

There are 8 cooling towers for the system. 4 cooling towers are placed at the rooftop of Block 3(cooling tower 1) and the other 4 are located at rooftop of Block 4(cooling tower 2). The cooling tower 1 is used for chiller 1 and cooling tower 2 for chiller 2. The usage will also alternate periodically.

3. Ice Cells

There are 45 ice cells that located underneath the parking area of Block 5 of S&T and 28 ice cells located opposite the Block 5.

Figure: Ice Cell Thermal energy storage may refer to energy is store in a thermal reservoir for later reuse. They can be employed to balance energy demand

between day time and night time. The thermal reservoir may be maintained at a temperature above (hotter) or below (colder) than that of the ambient environment. The principal application today is the production of ice, chilled water, or eutectic solution at night, which is then used to cool environments during the day.

The specification: Unit label: ice cell 1 -45 Description: TES tank Make: Dunham-Bush Model: Ts 240. Type: tube in tank Capacity rated: 240 Refrigerant tons hour(Rth) ; Norminal 10800 Rth Function to storage energy in ice produced by chiller at night.

4. Primary and Secondary Pump

Figure : Primary Pump

Figure : Schematic of Primary & Secondary Pump

The Specification: Brand Model Type Capacity Head Load : Regent : R10 / 12 CME : Horizontal Split Casing Pump : 4500 IGPM : 150 ft : 275 Hp

5. Condenser Water Pump

Figure : Condenser Water Pump

Figure : Schematic of Condenser Water Pump

The Specification: Brand : Regent Model : R200/300 BST

Type: Horizontal Split Casing Capacity: Head : Load : 2600 IGPM 90 ft 100 Hp

6. Heat Exchanger

Figure : Heat Exchanger

Figure : Schematic for Heat Exchanger The heat exchangers are used to transfer heat between two fluids. In the TES district cooling system, glycol and water are used in the flow of pipeline. The glycol function is not to produce ice. The glycol property that is will remain in liquid form even the temperature is below zero degree. So, during the ice making, the glycol will not freeze and still can transfer the cool temperature throughout the system. The ice temperature is transferred to the glycol so that the glycol could transfer the cool temperature to the building. The usage of heat exchangers, ice cells and the low temperature during ice making at night reduce the burden of chillers in operation. Specification of Heat Exchangers Amount of Heat Exchangers: 4 Manufacturer: Alfa Laval Model: MX25-BFG Type: Counter flow Flow rate (usgpm): Hot 2400 & cold 2400 In/out temp (C): hot 13.3/6.6 & cold 4.4/6.6 Heat exchanger (Rt): 1283.33 Function to exchange heat from glycol-water pipe line to water only

pipe line *Usgpm: US gallon per minute

7. Air Handling Unit (AHU) An air handler, or air handling unit (often abbreviated to AHU), is a device used to condition and circulate air as part of a heating, ventilating, and air-conditioning (HVAC) system. Usually, an air handler is a large metal box containing a blower, heating and/or cooling elements filter racks or chambers, sound attenuators, and dampers. Air handlers usually connect to ductwork that distributes the conditioned air through the building, and returns it to the AHU. Sometimes AHUs discharge (supply) and admit (return) air directly to and from the space served, without ductwork.

Figure : AHU Ducting AHU Components: Blower Air handlers typically employ a large squirrel cage blower driven by an AC induction electric motor to move the air. The blower may operate at a single speed, offer a variety of pre-set speeds, or be driven by a Variable Frequency Drive so as to allow a wide range of air flow rates. Flow rate may also be controlled by inlet vanes or outlet dampers on the fan.

Cooling / Heating Coil Large commercial air handling units contain coils that circulate hot water or steam for heating, and chilled water for cooling. The hot water or steam is provided by a central boiler, and the chilled water is provided by a central chiller

Filter Air filtration is almost always present in order to provide clean dust-free air to the building occupants. It may be via simple lowMERV pleated media, HEPA, electrostatic, or a combination of techniques. Gas-phase and ultraviolet air treatments may be employed as well. It is typically placed first in the AHU in order to keep all its components clean.

Control System Controls are necessary to regulate every aspect of an air handler, such as: flow rate of air, supply air temperature, mixed air temperature, humidity, air quality. They may be as simple as an off/on thermostat or as complex as a building automation system. Common control components include temperature sensors, humidity sensors, sail switches, actuators, motors, and controllers.

Figure : Building Air Distribution

8. Building Automation System (BAS)

S&T Complex applied Building Automation System (BAS). This system to ease the maintenance and operation services by controlling the whole system in the building included TES, elevators, and Fire Fighting System in one Control Room. The Fan Coil Unit and Air Handling Unit can be controlled in the room without going to each level to adjust the flowrate or just to on or off the units respectively. Overall system also can be monitored through BAS. It also can schedule the AHU and FCU operation.

Figure : S&T Layout in BAS

Figure : Schedule for AHU

4.1.3. Design Consideration and Operation Thermal energy storage can refer to a number of technologies that store energy in a thermal/ice reservoir for later reuse. They can be employed to balance energy demand between day time and night time. The thermal reservoir may be maintained at a temperature above (hotter) or below (colder) than that of the ambient environment. In this application a relatively standard chiller is run at night to produce a pile of ice. Water is circulated through the pile/cell during the day to produce chilled water that would normally be the daytime output of the chillers.

Operation:

The tank is filled with water submerged a polyethylene tube heat exchanger

A glycol solution (-3.3C) flowing inside the tubes causes the surrounding water to freeze

The chilled Glycol solution is typically provided by a chiller having 24 tons (84 kW) cooling capacity

To serve, the ice melted at a rate dictated by load

Requires 10 hours operation of a 24 ton chiller to fully freeze the water in the tank

When fully frozen, the ice cell stores 240 ton-hour (844 kWh) cooling capacity

The Glycol solution flows from the ice cell to the load device

Diagram 1: Operational flow of TES in S&T Chiller Plant Control Module i. ii. Automated chiller control and monitoring system. Powered by Opto22 hardware and software technology connected to the Dunham Bush NC25-4 Microprocessor to directly access control and data points. iii. iv. v. Precise and details access to the current system information Accessibility of system data results in faster response Computer aided scheduling that improves the utilization of machines and increases efficiency. vi. Real-time system data

Plant Operation Charging Mode i. 2 primary Ethylene Glycol Pump (PEGP 275hp each) each controlled by VSD. ii. Condenser water pumps (CWP) 1, 2, 3 and 4 with cooling tower (CT) 1 and 2. iii. Motorized valve V3 open with motorized valve V8, V9, V10, V12, heat exchanger closed.

iv.

3 chillers (900 RT each) start by sequence instruction from the chillers plant control module.

v. vi.

Modulating valve V2 open 100% and V1 closed. Flow rate in the range of 6000 GPM until 8000 GPM.

Plant Operation Discharging Mode i. 1 Primary Ethylene Glycol Pump (PEGP 275hp each) each controlled by VSD. ii. iii. Condenser water pump 1 and 2 with cooling tower (either CT 1 or 2) Motorized valve V3 closed with valve V8, V9, V10 for heat exchanger open. iv. 2 Chillers (900 RT each) will be start by the sequence instruction from the chiller plant control module. v. vi. Secondary chilled water pump (SCHWP) 3 and 4 start. Modulating valve V1 and V2 will modulate depends on the temperature set point 44 F. vii. Flow rate in the range of 5000 GPM until 7000 GPM

Thermal Energy Storage with Ice Storage was preferable to be installed in the complex due to spatial and the advantages gained. Thermal storage systems offer building owners the potential for substantial cost savings by using off-peak electricity to produce chilled water or ice. A thermal energy storage system benefits consumers primarily in three ways: 1. Load Shifting 2. Lower Capital Outlays 3. Efficiency in Operation

1) Load shifting Load shifting is primarily the main reason to install a TES system. Since TES works during off-peak energy, advantage of electrical utilities lower time-of-use rate could be taken. TES benefits in lower operating costs by saving money on electric bills and avoiding on-peak demand charges.

TES benefits on reduced demand for electricity during the peak demand periods. Many utilities offer cash incentives and rebates for installing or converting to TES. TNB offers off-peak rate which are less expensive and reduce the cost. o Low energy cost - approximately 20% lower. o Low TNB maximum demand (MD) charges

approximately 30% lower. o Lower production cost per unit of cooling energy. o No huge capital outlay for air-conditioning plant by building owner. o For TNB helps to improve (flatten) its daily load curve rational for off-peak tariff.

2. Lower Capital Outlays: Capital costs incurred are comparable to conventional air-conditioning system, with cost saved by using a small refrigeration plant. Storage systems let chillers operate at full load all night instead of operating at full or part load during the day. Depending on the system configuration, the chiller may be smaller than would be required for direct cooling, allowing smaller auxiliaries such as cooling-tower fans, condenser water pumps, or condenser fans. TES tanks allow a reduction of chiller capacity requirements. This is true for both new construction and system expansions. Lower equipment requirements translate to reduce maintenance needs. A TES system takes up less space and, when designed in conjunction with an air distribution system and installed during a building's construction phase, requires smaller ducts and fan motors. This can reduce spacing between floors and save money.

3. Efficiency in Operation: Conventional systems only operate at partial operating conditions most of the time. In contrast, the chiller used in a TES system operates at

full-load conditions for a shorter period of time while the system is being charged. The equipment's operating efficiency increases. TES system chillers always either run in its full efficiency or not at all. In other words the chiller operation is not dependent on the varying load profile of the building. Additionally, because the stored cooling equipment typically operates at night when outdoor air temperatures are cooler, heat rejection is improved. The condenser always sees low ambient dry and wet bulb temperatures. The net effect is usually a net decrease in kWh consumption; by anywhere from a few percent to a few tens of percent. TES system provides operational flexibility because the reserved storage capacity ensures enough buffers for varying loads of minimum and maximum demand. Chillers can be stopped during normal working hours for maintenance and service while the ice stored during off-peak period supplies cooling.

TES design flexibility PARTIAL STORAGE (LIMIT DEMAND) To meet all on-peak cooling To meet part of the cooling Limit demand, control to loads from storages. load from storage and part minimize site peak demand, directly from chiller, and low cost. discharged when the load is greater output. than the chiller FULL STORAGE PARTIAL STORAGE

4.1.4. References 1. Air Conditioning with Thermal Energy Storage. (n.d.). Retrieved July 25, 2011, from PDHengineer.com: www.pdhengineer.com/pages/HV-4005.htm 2. Aziz, M. (2010). Review on Performance of Thermal Energy Storage System at S & T Complex, UiTM Shah Alam, Selangor. 2010 IEEE Control and System Graduate Research Colloquium , 49-54.