Redesign of the chilled water circulation system in ATL project 2005-06

7.3 ROOT CAUSES

7.3.1 WATER FLOW RATE .
The total water flow rate required for the RF unit and different mills are
maintained by using two pumps of capacity 70m
3
/hr each at 70m head.
From the flow rate calculation we get the flow rate requirement for a single mill
is 0.87 lit/sec or 3.! m
3
/hr.
"n the e#isting system the cooling rate of the mill is not uniform and
sometimes$ during pea% loads the temperature of chilling water e#ceeds the
limiting &alue and it may cause brea%down of the system$ resulting in loss of
production.
The flow rate of water in the condenser of one RFunit is !3.' m
3
/hr
and for the efficient wor%ing the flow rate must be maintained at the standard
&alue.
"n order to meet the pea% load requirement of chilled water$ the flow
rate of water in the condenser may &ary and it may lead to the une&en cooling
of the system of the use of common pumps for the circulation of water to both
RF unit and mills.
7.3.2 Heat carrying capacity
"n the e#isting system heat load distribution is non uniform$ and at
times the chilled water temperature e#ceeds the limiting &alue and often
causes temporary brea%down of mills.
Dept. of ME MESCE Kuttipuram 37
Redesign of the chilled water circulation system in ATL project 2005-06
Major ca!e!
"n e#isting system the RF units directly supply the chilled water to
&arious mills to meet the requirement. (t pea% load condition the RF
unit cannot supply required chilled water at sufficient flow rate.
"n the e#isting system the there is only one chamber $
The e#isting chamber is used only for the recirculation of hot water to
RFunit.
The bypass arrangement causes wastage of heat in the chamber.
7.3.3 "o#er Con!$ption
The areas of power consumption are$
RF )*"T +,-'0TR .!,0TR/
01"22"*3 4(T5R 6)76
08*95*:5R 6)76:
0882"*3 T845R F(*
"n this system the 3 RF units are wor%ing round the cloc% for supplying chilled
water. 1ence the power consumption is &ery high.
Dept. of ME MESCE Kuttipuram 38
Redesign of the chilled water circulation system in ATL project 2005-06
7.% &'EAS
7.%.1 Water F(o# Rate
4ater flow rate can be controlled by modifying the pumping system. we
can use separate pumping system for the circulation of chilling water to
RFunit and &arious machines.
7.%.2 Heat carrying capacity.
"n this we separate the e#isting water collection chamber into two separate
wells. That is$
18T 4522
0829 4522
7.%.3 "o#er Con!$ption
"n this system we are use only one '0TR and one !,0 TR units
at a time to meet the a&erage load. 8ne '0 TR unit is used as stand by unit.
;y switching off one RF unit we can sa&e energy.
Dept. of ME MESCE Kuttipuram 39
Redesign of the chilled water circulation system in ATL project 2005-06
7.) COU*TER MEASURES
7.).1 "ropo!e+ !y!te$
"n the proposed system we separate the collection chamber into
hot well and cold well and separate pumps are installed for regulating the
required flow rate to the system.
The chilled water directly comes from the RF unit to the cold well. From
there the chilled water is supplied to the &arious machines with the aid of
pumps. The returned water from the &arious machines collected into the hot
well and from the hot well the water is pumped to the RF unit and completes
the circulation.
"n the proposed system instead of three pumps of <0hp$ we ma%e use
of ' pumps of capacity ,0hp each. 8f the ' pumps$ 3 pumps are used for the
circulation of chilled water to &arious machines and the other 3 pumps used to
return the hot water to the RF unit.
The ad&antage of using ' pumps instead of 3 pumps is that$ a steady
flow rate can be maintained while the electrical consumption remains the
same.
7.).2 C,i((e+ #ater !y!te$ #it, ,ot an+ co(+ #e((
These types of system ha&e two independent of chilled water circuits
with separate pumps. 8ne to circulate a steady rate of water flow through the
chiller %nown as the primary pump and second %nown as the secondary pump
for the process circuit.
The circuits are lin%ed through a tan% which has two compartments$ one
recei&ing the chilled water from the chiller and the second recei&ing the warm
water from the process. The primary pump circulates water from the warm
compartment of the tan% through the chiller and then to the cold compartment.
Dept. of ME MESCE Kuttipuram 40
Redesign of the chilled water circulation system in ATL project 2005-06
The secondary pump circulates the chilled water from the cold compartment
to the process equipment and bac% to the warm compartment of the tan%.
Thus a continuous and steady flow rate of water through the chiller is assured.
To ma%e up for the loss of water through glands of pumps and &al&es$ a ma%e
up line with a float le&el control is connected to the warm compartment of the
tan%.
Dept. of ME MESCE Kuttipuram 41
Redesign of the chilled water circulation system in ATL project 2005-06
!. Refrigeration unit
,. 6ump
3. 7a%e up water tan%
<. 3= way &al&e
Dept. of ME MESCE Kuttipuram 42
Redesign of the chilled water circulation system in ATL project 2005-06
Dept. of ME MESCE Kuttipuram 43
Redesign of the chilled water circulation system in ATL project 2005-06
7.).3 Water F(o# Rate.
"n this system we partition the collection chamber into hot and cold
wells. 4e use separate pumps for the hot and cold well.
That is 70 m
3
/hr$ 3m head$ ,016$ two pumps for circulating the chilled water
and same standard two pumps for the hot water circulation to the RF unit.
"n the new system we can maintain uniform flow rate in the
different mills without considering the flow rate of RFunit.
(lso we can meet the different load requirement in different mills by ad>usting
the &al&e at the deli&ery side of the cold well.
7.).% Heat Carrying Capacity
"n this we separate the e#isting water collection chamber into two separate
wells. That is$
18T 4522
0829 4522
(lso we modify the pumping system$ separate pumps for two wells.
Two ,016pumps for the hot water circulation to RF unit.
Two ,016pumps for the chilled water circulation to &arious mills.
"n the new system chilled water from the RF unit is directly supplied to the
cold well. From the cold well$ the chilled water is pumped to the &arious mills.
This system controls the temperature of the chilled water within the limits.
The different load conditions can easily be met by this system. ;ecause the
Dept. of ME MESCE Kuttipuram 44
Redesign of the chilled water circulation system in ATL project 2005-06
cold well has sufficient quantity of chilled water at all times the supply of
chilled water within the temperature limits can be met with ease.
7.).) "o#er con!$ption
RF U*&TS
"n this system we are use only one '0TR and one !,0 TR units at a time to
meet the a&erage load. 8ne '0 TR unit is used as stand by unit. ;y switching
off one RF unit we can sa&e energy.
4hen the system is wor%ing it ta%es power in the rate of !amps for !TR.
The "dle 2osses for the '0 TR )nit ?30amps
CO*'E*SER "UM"
"n proposed system we can switch off one condenser pump for the cooling
tower and sa&e energy.
Dept. of ME MESCE Kuttipuram 45
Redesign of the chilled water circulation system in ATL project 2005-06
7.- RESULTS
7.-.1Energy .a(ance
5nergy balance is done by comparing the e#isting and proposed
system.
4e analy@e the heat capacity of the e#isting chilled water system and
the total requirements of the different mills. 9uring pea% load 2osses are also
considered for the calculation.
E/i!ting !y!te$
For one roller energy requirement is ?,A.33%w
For 30 rollers ?,A.33B30
?880%w
(&ailable capacity 0 rated 1 ?8<%w
2osses ?8%w
*et a&ailable energy capacity ?7'0%w
From the abo&e analysis we can infer that this system cannot meet the
requirement during pea% load.
"ropo!e+ !y!te$
8ut of , readings ta%en in 8 hrs$ only < readings are higher than ,<0 TR
that is the +capacity of RF unit / +!'C/.
4ith the e#isting system chilled water temperature cannot be maintained at
the below specified le&el during this pea% load time.
4ith proposed system$ as the chilled water temperature in the sump is
reduced well below during the off load time and hence the pea% load can be
met with this &ery low temperature chilled water.
Dept. of ME MESCE Kuttipuram 46
Redesign of the chilled water circulation system in ATL project 2005-06
7.-.2 WATER FLOW RATE.
CALCULAT&O*S
Total no of mills ? !
Total no of rollers ?!B,
?30
Flow rate requirement for
one roller ?0.87lit/sec
Required flow rate
for 30 rollers ?0.87B30 lit/hr
?0.87B30B3'00
23%.) $
3
4,r
The capacity we ha&e ?,B70
?1%5 $
3
4,r
Fro$ t,e a6o7e ca(c(ation it i! c(ear t,at t,e re8ire+ 9(o# rate i! ea!i(y
$aintaine+ in t,e propo!e+ !y!te$.
7.-.3 HEAT CARR:&*; CA"AC&T:
The different load conditions can easily be met by this system. ;ecause the
cold well has sufficient quantity of chilled water at all times the supply of
chilled water within the temperature limits can be met with ease.
From load conditions$
The a&erage load of the plant is ?!0TR
Dept. of ME MESCE Kuttipuram 47
Redesign of the chilled water circulation system in ATL project 2005-06
Total plant capacity is ?,<0TR
;y using this system one '0TR unit can be used as stand by unit.
;ecause !80TR is sufficient for meeting the a&erage load.
7.-.% "o#er Con!$ption
The "dle 2osses for the '0 TR )nit ?30amps
The 6ower ?D3E" 08:F
?!.73,B<<0B30B0.A
?,0G4/1R
That "s For 8ne :hift ?,0B!0 ? ,00%4.
,00%w energy can be sa&ed by using this system.
CH&LLE' WATER "UM"
The total pump rating remains the same after modifying the system.
"n e#isting system$ power consumption ? 30B<0
?!,0hp
"n proposed system ?'0B,0
?!,0hp
That is the power consumption is same as before.
CO*'E*SER "UM"
"n proposed system we can switch off one condenser pump for the cooling
tower and sa&e energy.
Dept. of ME MESCE Kuttipuram 48
Redesign of the chilled water circulation system in ATL project 2005-06
C,apter<=
Co!t 6ene9it ana(y!i!
The %ey steps in&ol&ed in determining whether a pro>ect is worthwhile or not
are$
5stimates the cost and benefits of the pro>ects
(ssess the ris%iness of the pro>ect.
0alculate the cost of capital.
0ompute the criterion of merit and >udge whether the pro>ect is good or
bad.
There are se&eral criteria that ha&e been suggested by economist to >udge the
worthwhile ness of capital pro>ects. :ome are general and applicable to wide
range of in&estments.
The important criteria are$
*et present &alue.
"nternal rate of return.
6ay bac% period.
=.1 "A: .AC> "ER&O'
The paybac% period is the length of time required to reco&er the initial cash
outlay on the pro>ect. (ccording to the paybac% criterion$ the shorter the pay
bac% period the more desirable the pro>ect. The firms using this criterion
generally specified the ma#imum acceptable pay bac% period.
Dept. of ME MESCE Kuttipuram 49
Redesign of the chilled water circulation system in ATL project 2005-06
=.2 Co!t ana(y!i!.
"n this analysis we are analy@ing the financial benefits$ get from the proposed
system and the &arious costs incurred for the modification.
The ma>or costs we ha&e to meet are the cost of pump. Total si# pumps are
required for the modification. 8ut of this$ three are a&ailable in the factory.
Sa7ing!
5nergy sa&ing ?,0%4/hr
For one year ?!,B,0B3,
2=%%=5?#
0ost of one unit of
5lectricity
?Rs3.
For one year sa&ing 2R! 23)-=54<
Co!t!
0ost of one ,0hpH
3m head pump ?! la%h
For 3 pumps ?3 la%h
"nstallation and miscellaneous ?! la%h
Total cost 2% la%h
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Redesign of the chilled water circulation system in ATL project 2005-06
=.3 "ay .ac? "erio+ Ca(c(ation
Total 0ost ?% la%h
8ne month sa&ing ?,<'<0
"ay 6ac? perio+ 2%5555542%-%5
21-.2 $ont,!
Dept. of ME MESCE Kuttipuram 51
Redesign of the chilled water circulation system in ATL project 2005-06
Conc(!ion
"n our pro>ect we are redesigning the chilling water circulation system for
obtaining ma#imum efficiency with minimum utili@ation of energy
From the analysis we can conclude that the design is cost effecti&e and
efficient.
Dept. of ME MESCE Kuttipuram 52
Redesign of the chilled water circulation system in ATL project 2005-06
Re9erence@
REFRIGERATION AND
AIR CONDITIONING C P ARORA
REFRIGERATION ANANTHA NARAYANAN
!"ee-india!nice!in
www!em!ea!org
Dept. of ME MESCE Kuttipuram 53