Low Energy HVAC Systems Installed in IPCA Plant

Low Energy HVAC Systems Installed in IPCA Plant At Pithampur (Indore) SEZ By Surendra H. Shah, Member - ISHRAE

IPCA Pithampur SEZ Project Parameters • Area: 100, 000 Square Feet • Ambient Summer 40ºC db, 26ºC wb. Monsoon 35ºC db, 30ºC wb. • Inside: Varies between 22ºC to 24ºC db, 40% to 55% rh. • Load As Calculated for Standard Chiller System 525 Tons • Load Reduction Tons –R-15 insulation 150 –Fresh Air Pre-cooling 50 200 • Reduced Load • Energy Demand –Standard Chiller System –With Reduced Load, –Zon. All™ System & Tons 525 EER 13 325 Tons Energy 485 k. W Difference –Evaporative pre-coolers 325 16 244 k. W 241 k. W • Savings in water: Chiller =35, 700 lit/day For 300 days=10. 71 million lit. /yr Pre-coolers=12000 lit/day*180 days= 2. 16 million lit/yr

IPCA Pithampur SEZ Saving By Load Reduction • • 1. Saving by using R-15 above- deck insulation • • • U-factor for bare roof = 0. 52 Btu/Hr. /Sft With R-15 insulation =1/15=0. 067 Btu/Hr. /Sft Equivalent temp. difference = 52°F For 100, 000 Sq. Ft. , saving = 52*(0. 52 -0. 067)*100, 000/12000 Saving is 196. 3 TR. Say 150 Tons Saving by Indirect Pre-cooling of Fresh Air. • 50 Tons Total saving by load reduction – 200 Tons

IPCA Pithampur SEZ Energy Saving Zon. All™ Pumpless, waterless Central Refrigeration Plant • It works without water, pumps, water piping, cooling tower, boiler or heater • 75 TR Unit cools and heats 20 AHUs • It has very few very simple controls • Total 325 TR • Substantial savings in power and water • No fouling or de-scaling of tubes • Peak efficiency lifelong • Simple and easy maintenance

IPCA Pithampur SEZ Energy Saving Air Cooled Condensers with Evaporative Pre- Coolers Each of these three square condensers cools one 25 TR Scroll compressor of the Zon. All™ unit below Each of the four rectangular units around each condenser is an evaporative cooler that starts if the ambient goes above 35ºC. The condenser air is always below that. Near water cooled performance using much less water that needs no softening, because they work for a few hours a day only in summer

IPCA Pithampur SEZ Energy Saving Indirect Evaporative Coolers For Fresh Air • The fresh air load, that was calculated to be 221 Tons, was reduced by 50 Tons in summer by using these multistage indirect evaporative precoolers

IPCA Pithampur SEZ Energy Saving Comby® Low Humidity air conditioners ® • Comby Low Humidity units are stand-alone machines that maintain clean room conditions at a very low energy cost. • They have their own DX systems that recover sensible heat from return air and add it to supply air as reheat. Latent heat is also recovered and used as extra reheat when room sensible load is low. • They use, not heat pipes, but a patented dual evaporator system that also sub-cools the liquid.

IPCA Pithampur SEZ Energy Saving • This is all the piping and controls as installed in a typical AHU fed by the Zon. All™ DX central cooling and heating units.

IPCA Pithampur SEZ Energy Saving Ductless High Air Circulation Units For Storage Areas Two techniques were used to save energy and increase storage space in store rooms. Double the normal air quantity since the load is mostly sensible thus increasing EER Ductless installation in the passages, Absence of ducts allows stacking up to the slab bottom

IPCA Pithampur SEZ Energy Saving Direct Natural Cooling Of Plinth Slab To Create Negative Load Note: This is not added to the savings estimate because it can’t be predicted accurately. It could be as high as 200 Tons • Therm-O-Drain™ System has pipe grids under the ground floor tiles. • The grids connect to heat exchangers inside the Heat Rejection Units (HRUs) located on the roof. • The entire system is under high vacuum. The grids contain water that boils at low temperature, cooling the slab; the vapour goes to the HRUs. • The heat exchangers also function as cooling towers and condense the vapour to water, which returns to the grids by gravity. • Thus a large amount of heat is removed from the slab by 24/7 operation, creating a negative sensible load in the summer

IPCA Pithampur SEZ Teamwork • Our Site Team Our Office Team Panasia Engineers Private Ltd. 3 -B Thacker Estate, Mumbai 400011