ThermaServe, Inc. Case Studies______

ENERGY EFFICIENCY CASE STUDY MEDICAL FACILITY Facility:   Medical Outpatient Facility A mission critical medical outpatient facility with operating rooms that has to maintain HVAC and comfort control for daily operations. Problem:   Inefficient operation without reserve capacity Two original 179-ton constant speed chillers with Y delta standard starters providing a combined 358-ton cooling capacity, however, there was a loss of cooling capacity over time of 20%, down to a combined 285-tons. The documented energy consumption to cooling capacity ratio was .95Kw per ton. Whereas, advanced technology at design conditions provides an efficiency level of .55Kw/Ton to .65Kw/Ton availability. Furthermore, with these losses the two original chillers were borderline at maintaining the present cooling load without reserve capacity. Solution:   Replace one of the existing chillers with a Variable Speed Drive (VSD) driven 350-ton chiller. The improved chiller capacity provides the needed cooling capacity at a reduced level of energy consumption, with one of the original chillers left in place for reserve capacity. A design efficiency level of .62Kw/Ton was gained, and with an integrated part load value of .394 now achieved, only by having the Variable Speed Drive, the system is much more energy efficient. In other words the system actually becomes more efficient at part load, which was not possible with the standard constant speed chiller. Payback: 4.5 Year Payback Using a simple payback method based on the present utility costs, the cost of the project and a reduction in yearly maintenance costs anticipated the payback for the project will be 4.5 years. This payback for the retrofit combined with the reserve capacity gives peace of mind that this mission critical facility will continue to operate. Click here to download file complete with photos

ENERGY EFFICIENCY CASE STUDY PUBLIC SCHOOL Facility:   Public Education Facility A grade 9 through 12 high school in North Florida Problem:   Gaining more energy efficiency and protecting the environment The School board was tasked with saving energy by looking at existing older HVAC & Chiller systems for opportunities to gain energy and cost savings. The school had two 400Ton Chillers with R11 refrigerant(a CFC), Y-delta starters with constant speed drive system. The Chilled plant configuration was a primary/secondary loop design. Frequently with this design, warm secondary return water(approx 54 degrees F) was mixing with primary chilled water at 44 degrees and pumped by secondary pumps to the school cooling load at elevated mixed temperatures of approximately 48 degrees. A loss of capacity to dehumidify was the main consequence of this condition and would precipitate the start and continued operation of a second 400Ton Chiller and its related auxiliary equipment even though the first chiller was not yet operational at 100% capacity. This resulted in a very inefficient operation of multiple chillers at loads under 50% capacity. A very inefficient condition. Solution:   Changing the design and replacing one chiller We converted the primary/secondary loop design to a variable primary design by removing the primary chilled water pumps, and installing a minimum flow chilled water by-pass to ensure the manufacturers recommended minimum flow to operate chillers. This prevented the necessity to start the second chiller before the first chiller was operating at 100% capacity. In fact since we made this retrofit conversion, there hasn’t been a need to run the second chiller and it’s related auxiliary equipment. As part of this energy retrofit, we replaced one chiller with a Variable Speed Drive (VSD) driven 400-ton chiller using R-134A refrigerant. We also adjusted the Variable Frequency Drives (VFD’s) to control chilled water pumping volume, installed VFD’s on the cooling tower fans and set condenser water control point at 55 degrees with a wet-bulb reset to conserve tower fan energy. The 55 degrees condenser water control point, when conditions allowed, permitted the new variable speed chiller we installed to operate at efficiently as low as .33Kw Ton. Payback:   20% Energy Reduction Not only was the CFC refrigerant replaced, protecting the environment, and a better solution to removing more moisture out of the air, but a 20% energy savings was gained. Click here to download file complete with photos

CARRIER 19C 1200 TON CENTRIFUGAL CHILLER REPAIR CASE STUDY Facility:   Class "A" High Rise Repair Parameters:   Inlet guide vanes were seized Repair Challenges / Repair Rigging & Tools: No room for rigging and had to custom build gantry to rig / Custom Manufacture of Tools Repair Time / Constraints / Opportunities:  Machines have to be repaired in place due to location on 36th floor  Click here to download file complete with photos

TRANE CVHF CENTRIFUGAL CHILLER OVERHAUL CASE STUDY Facility:   Municipal chiller plant servicing a major hospital  Repair Parameters:   Replaced a failed bearing Repair Challenges / Repair Rigging & Tools:  Special rigging required, some individual components weighed nearly 3 tons Repair Time / Constraints / Opportunities:  Made another on-time repair Click here to download file complete with photos

CARRIER 19EB CENTRIFUGAL CHILLER CASE STUDY Facility:   Class "A" High Rise Repair Parameters:   Eight Year Stop - Mechanical Inspection Repair Challenges / Repair Rigging & Tools:  Low Overhead / Creative rigging procedures were required Repair Time / Constraints / Opportunities:  Detected bearing wear and therefore able to replace during inspection Click here to download file complete with photos

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