INTRODUCTION FOR AIR CONDITIONING ENERGY EFFICIENCY & INDUSTRIAL VENTILATION TECHNOLOGY FOR MANUFACTURING PLANTS
From the national perspective, the importance of energy conservation (EC) cannot be overemphasised. The benefits of energy conservation are significant to the nation’s economy and performance in the management of its environment. Improving energy efficiency will lead to significant cost-savings and thereby improving competitiveness. Energy conservation activities will also help to conserve the usage of the nation’s limited natural resources and at the same time reduce the negative environmental impacts. The implementation of energy efficiency (EE) programmes will focus on energy-saving features in manufacturing plants. In this regard, EE features and establishing comprehensive energy management systems will be encouraged. In addition, the manufacturing sector will be encouraged to implement EE measures including improvements in plant, equipment and processes.
COURSE OVERVIEW
This course is industry designed, to provide a broad understanding of the improvement methodology, concepts, and process. The methodology is presented with case studies and examples drawn from service, business process and manufacturing applications. With a heavy practice orientation, as much as a third of your time will be spent working through interactive practical exercises and assessments. This course is designed as an introduction to concepts and methodology.
COURSE OBJECTIVES
This training program is designed to provide an understanding of engineering related problems related to industry globally and a clear sense of what is required to effectively structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem solving initiative within their organization.
LEARNING OUTCOMES
On successful completion of this course, the participant should be able to:-
- Understand the benefits and implications of EC and EE problem solving programs, and relate the concepts to the overall business mission and objectives.
- Think about his/her organization as a collection of processes, with inputs that determine the output.
- Use the concept of EC and EE systems engineering problem solving to evaluate the capability of a process or organization.
- Recognize the engineering problem solving model used to improve processes.
- Recognize the organizational factors that are necessary groundwork for a successful engineering problem solving program.
- Integrate the EE and EC systems engineering problem solving program effort with other process improvement initiatives.
METHODOLOGY
- The latest educational methods and strategies will be utilized.
- The course is designed to maximize delegate participation.
- Questions and answers are encouraged throughout and at the daily wrap-up sessions. This gives participants the opportunity to discuss with others and the presenter their specific problems and appropriate solutions.
- The course shall be conducted through lectures, case studies, group discussions and exercises to reinforce participant’s learning.
- Participants are required to bring along their scientific calculators, writing note books / writing material, pens, pencils, rulers etc.
WHO SHOULD ATTEND
Manufacturing, process, executives, managers, maintenance personnel, operational managers etc.
COURSE FORMAT
The course consists of formal content presentation interspersed with content quiz sessions. The presenter’s style involves intensive participant participation.
COURSE CONTENT
DAY 1
Motors for Air Conditioning Energy & Industrial Ventilation
- Guideline on Equipment Energy Efficiency
- Motor selection
- High Efficiency Motor
- Efficiency Classification
- Efficiency Testing Requirements
- Energy and Cost-Saving Potential
- Cost Premium for High Efficiency Motors
- Savings in Running Cost
- Motor Sizing
- What to Consider When Selecting a Motor
- How to Estimate the Efficiency of Existing Motors
- Guideline for Best Practice
- Operation and Maintenance
- Proper Commissioning
- Maintenance Records
- Motor Set-up and Alignment
- Motor Cleaning
- Motor Lubrication and Bearing Maintenance
- Motor Condition Assessment
- Electrical Performance Assessment
- Switching Off When Not Needed
- Reducing Motor Loads
- Slowing Down Loads for Pumps and Fans
- Motor Repair
- Decision to Replace or Repair the Failed Motor
- Other Factors Affecting Choice between Replace and Repair
- Variable Speed Drives
- Best Practice Guides
- Case study on payback estimates on buying a new high efficiency motor (HEM) compared torepairing a standard motor
- Approximate frequency of motor inspection and testing
- Case study – Energy Savings by retrofitting
Chillers
- Guidelines on System Design & Chiller Selection
- Cooling Load Estimates
- System Diversity and Operating Regimes
- Types of Chillers
- Chiller Selection Criteria
- Equipment (Chiller) Energy Efficiency Rating
- Guideline for Best Practice
- Guidelines for Operation and Monitoring
- Guidelines for Inspection and Maintenance
- Case study 1: Installation of automatic controllers to improve energy efficiency of chillers in a hotel
- Case study 2: Replacement with energy-efficient chillers
Cooling Towers
- Guidelines on System Design & Equipment (Cooling Tower) Selection
- System Diversity
- Types of Cooling Towers
- Cooling Tower Selection Criteria
- Equipment (Cooling Towers) Energy Efficiency Ratings
- Guidelines for Best Practices
- Guidelines for Operation and Monitoring
- Operation
- Monitoring
- Weekly Checklist
- Guideline for Inspection and Maintenance
- Recommended Inspection and Maintenance Schedule
- Case Study 1
- Case Study 2
- Suggested Methods of Energy Savings for Cooling Towers
DAY 2
Ventilation & Exhaust Fans
- Types of Fans used in the HVAC Industry
- Centrifugal fans
- Axial flow fans
- Fan selection criteria
- Fan performance
- Equipment (fan) energy efficiency ratings
- Guidelines for Best Practice
- Guidelines for Operation and Monitoring
- Weekly Checklist
- Guidelines for Inspection and Maintenance
- Recommended maintenance schedules
- Case Study 1 : Energy Savings by Retrofitting VSD to an AHU Fan for a Hotel Lobby Application
- Case Study 2 : Replacement of an Industrial Drying Fan
- Suggested Methods of Energy Savings that will Reduce Fan Loads
Pumps for Air Conditioning Systems
- Overview of Good Design and Management Practices
- Design
- Selection of pumps
- Pump efficiency
- Piping systems
- Analysing existing pumping system effectiveness for improvement opportunities
- Achieving lower energy consumption with lower head requirements
- Impeller diameter change
- Variable Speed Drives
- Guidelines for Best Practice
- Maintenance and Operation Management
- Avoiding cavitation
- Avoid air ingestion
- Checking for Piping Losses
- Varying Pump Performance
- Maintenance
- Example of Best Practice for Pumps
- Maintenance Notes and Other Considerations for Pump Users
- Energy-savings – Example 1
- Energy-savings – Example 2
Compressors for Refrigeration Equipment
- Compressor Types
- Compressor Selection Guide
- Compressor System Design
- Guideline on Best Practices
- Managing Compressor System Leaks
- Methods in measuring magnitude of leakage
- Leak detection and repair program
- Potential leak areas
- Repair programs and fixing leaks
- Managing Pressure Drop and Controlling System Pressure
- What causes a pressure drop?
- Minimizing pressure drops
- Maintaining Compressed Air Dryness
- Maintenance of Compressed Air Systems to Maintain Equipment Efficiency
- Management / System Operators / System Owner’s Role
- Waste Heat Recovery
- Compressed Air System Surge
- Case study
- Guide to comparison of Centralised and Decentralised Systems
Question &Answer Session
End of Workshop
