During IDEA’s annual District Energy Conference and Trade Show, in Indianapolis, USA, Juan Ontiveros, the ex-Chair of IDEA and the Executive Director of Utilities and Energy Management at the University of Texas at Austin, reported achieving 0.329kW/TR (for January 2010) at the district cooling scheme on campus. B Surendar of Climate Control Middle East caught up with him in Indianapolis to find out how. excerpts from the interview…

In your words, the university achieved 0.329kW/TR in January 2010. How did you manage to do so?

Where you start is important, and you start by having metering. Until you know the actual performance of each unit, each sub system and total, you cannot change. So you need to calibrate the instruments and meters. Twelve years ago, it was manual. It was, “Push this button and turn the valve.” I invested in automation and metering. Then, the question was, “Now that I have this, what do I do with the data?”

We need to look at overall performance and individual components and how to optimise the bottom-line. We started with just six data points on each chiller and turbine. We looked at opportunities at each data point, and we saw some obvious bottlenecks. We confronted several questions: “Do you have the right pipe size?” “Is there too much friction?” “Are your valves operating correctly?” “Is it too high or too low a flow?” “Is it because of an equipment problem?” “Is it a case of the pump not working or the valve being wrong?” “Is the pipe size wrong?”

Then, we did a lot of ‘what-if’ scenarios. We asked ourselves, “What happens to the total cost if you change a chiller?” In effect, we did cost-benefit analyses and lifecycle analyses. When you have everything instrumented, you have data. Then, you have to look at which data to use. We went for graphic tools to understand the data better, and it helped. If you don’t measure and model, you can’t improve.

How did you finance this vast study?

We took care of the easy things. It’s been a gradual process. The model also gives the operator a better understanding of how the total system works and not just the chillers or the pumps. When you have a model, you can see all the scenarios and make all the combinations. Our chiller stations run automatically. All the operator does is to start or stop the chillers.

The chiller station performance depends on many variables: weather, humidity, temperature and load. Also, if you have a VFD, the question was, “What speed should I have my chiller on?” The model controls all the variables and knows what the optimum performance curves are. It’s too many variables for humans to manage; that’s why you need a model. The model forces you to be honest. If I am losing on efficiency, maybe the weather is a factor.

The other side is people. I mean, people with knowledge, training and with a different mind-set. Earlier, it was: “I am an operator, and my job is to keep the car on the road. And as long as I do that, I am happy.” Today, the operator is also looking at reliability and efficiency.

You can get very high reliability by using redundant equipment. That’s the easy way. Now, the question is, “If I need only one pump, why run three?”

The maintenance people also have to change. From being a mechanic, you are working with digital controls. So we need this mindset. We use people that calibrate and make sure instrumentation is working as it should. So we have a whole new approach and highly skilled people.

If you go this method, you need less people. From 230 people, we are 179 people now. They are paid higher, because they bring higher skills.

When that mechanic or technician needed help, I created a middle manager. The guy is responsible for control and maintenance. The middle-managers are your future plant managers. It’s called succession management planning. If one of them is absent, the other can offer support.

Every mechanic has to complete 258 hours of training, and it is test-based. We want to raise the skill and knowledge level of people, and it makes you a strong organisation. We have smarter people. We empower people. My people also have a lot of authority. They call me now and say, ‘Hey, Juan, this is what we did.’ They don’t say, ‘Hey, Juan, what do we do?’

If they do make a mistake, it’s my mistake. If they make a success, it is their success. I will tell my boss that they are the reason for success. If there are repeated mistakes, we do incident analysis. We try to learn from the mistakes. We are good because of the culture we have. I want my people to take risks… calculated risks, to become more efficient. You have to encourage that. Once they don’t take risks, they are no longer efficient. They are just keeping the car on the road.

In short, it is all down to the right type of equipment and understanding the people. These are keys, which have helped us achieve the situation where we use the same amount of energy, though we are today cooling eight million square feet.

There is no silver bullet for our success. It’s work and transformational process, and I am proud of it. I come up with crazy ideas, but they have to do it. When you design a plant, you have to handle a peak, but most of the time, you operate at low demand. So the trick is how to operate at a peak and yet operate at low most of the times.

Ocean Optics

Ocean Optics, supplier of solutions for optical sensing, has announced that it has added SteadiQ to its range of applications for its field-portable spectrometers. Ocean Optics claims that SteadiQ provides a temperature-controlled atmosphere, helping stabilise temperature effects and eliminate temperature drift in inclement conditions or extreme temperatures from -20C to 50°C.

The portable device, claims the manufacturer, assures more accurate, reliable results in field applications, including solar irradiance, volcanic observation, greenhouse monitoring, and industrial environments, such as cold food storage.

Product features:

• Available in UV (200 to 1,100 nm) and Vis-NIR (400 to 2,500 nm) versions, the SteadiQ interfaces directly with Ocean Optics’ USB2000+, USB4000, HR2000+, HR4000, Maya2000, Maya2000 Pro, QE65000, and NIRQuest spectrometers.
• In extreme hot or extreme cold conditions, the unit operates independently of outside temperatures.
• It connects easily to the spectrometer with preconfigured plug-ins and communicates via the spectrometer’s USB port.

Victaulic

Claiming that it offers fast and dependable installation, durable performance and is cost effective for maintenance and retrofit applications, Victaulic has announced the launch of AquaFlex stainless steel sprinkler fitting range in Europe, Middle East, Africa and India.

Victaulic further claims that AquaFlex requires fewer man hours to install whilst lowering shipping costs with its more compact form. It is a convenient and safe solution, which is easier to position than rigid piping, says the manufacturer.

Victaulic lists the following product features and advantages:

• The sprinkler fittings are suitable for commercial suspended and hard ceilings and for round or square duct work to provide fire protection where combustible gasses may be present.
• The fittings are available in two different types – a braided system (FM Approved) and unbraided system (cULus 2443 Listed), with system availability depending on region and on application.
• The range comes preassembled and consists of a flexible stainless steel hose, available in 790 to 1,830 mm (31 to 72 inches) in length, a reducer for connecting the sprinkler and a branch nipple for attachment to the piping system. A versatile and time-saving, installation-ready bracket is also included when ordered as a kit.

“We are very excited about the launch of the AquaFlex range,” said James Keown, Victaulic fire protection engineer Middle East, about the new product. “Not only do the new products provide an intuitive, dependable solution for our customers, but they also install up to 10 times faster than rigid piping systems – saving time and money.”

According to Victaulic, the AquaFlex line also includes the patent-pending 1-BEE2 installation-ready bracket that installs up to five times faster than any competitive bracket technology. It further added that the new bracket provides easy three-dimensional positioning of the sprinkler and secures mounting to the ceiling grid without tools, allowing instant, centre-of-tile sprinkler positioning.

Victaulic adds that a variety of optional accessories are now available, including the Victaulic FireLock Style 922 FireLock Outlet Tee – for mechanical hole-cut branch-line installation. Further, the AquaFlex hose, 1-BEE2 bracket and other accessories are also available for purchase separately, says the manufacturer.

“The AquaFlex patent-pending 1-BEE2 bracket is designed to firmly grip the ceiling grid, locking the sprinkler into proper operational position,” said Keown. “The unique, adjustable open-gate centre bracket saves time and money during installation by allowing for easy pressure testing of the system and final placement of the sprinkler head, after the ceiling grid is installed,” he added.

E+E Elektronik

Claiming that it has been specially developed for OEM applications and high-volume production, E+E Elektronik has launched CO2 sensor module EE892, which it says consumes less power. It supports this claim by saying that features, such as an adjustable measuring interval, enable optimum adaptation to specific applications while maintaining an average current consumption of less than 60μA.

This, says the manufacturer, makes the EE892 CO2 sensor module the ideal battery-operated, energy-saving device.

E+E Elektronik lists the following product features and advantages:

• The digital interface and compact design facilitate clear-cut integration in mobile and energy-sensitive applications such as, data loggers or demand-controlled ventilation.
• The CO2 load cell is based on infrared technology (NDIR) and, thanks to the patented E+E autocalibration process, it is maintenance-free.
• Ageing effects are compensated automatically to guarantee outstanding long-term stability.
• The measuring accuracy and the large measuring range of up to 10,000 ppm make the EE892 an ideal tool for universal and flexible applications.
• E+E also provides corresponding application notes to enable easy integration of the CO2 sensor module in specific customer applications.

Being held for the first time in Las Vegas

The 2011 AHR EXPO (International Air Conditioning, Heating, Refrigerating Exposition) is slated to be held from January 31 to February 2, at Las Vegas Convention Center

Las Vegas, Nevada, the expo organiser has announced. The HVAC/R’s event, which is produced and managed by the International Exposition Company, attracts exhibitors and attendees from all facets of the industry around the world, and will include contractors, engineers, dealers, distributors, wholesalers, OEMs, architects, builders, industrial plant operators, facility owners and managers, agents and reps, the organiser claimed.

The announcement have listed the following features and attractions of the expo:

• More than 1,800 exhibitors from every segment of the HVAC/R industry
• More than 360,000 net square feet of exhibition space
• More than 40,000 visitor and exhibitor personnel                     

For further information: Visit the AHR Expo website at http://www.ahrexpo.com or contact 2032219232 or email to info@ahrexpo.com.

Claims that future-oriented metering is basis for smart grids

At this year’s Metering Europe conference and exhibition in Vienna, Siemens presented, what it called ‘a holistic smart metering solution’ as a key component for setting up smart grids. The announcement was made by the Energy Sector, Power Distribution Division of Siemens. The solution consists of an AMIS automated metering and information system and an Energy IP metering management system, it said.

Siemens explained that a data hub Energy IP integrates existing utility IT systems via a SAP-certified interface into the smart metering infrastructure. Utilities can thus utilise smart metering across their business – from metering to billing and from operations control to network planning. The smart metering solution provides a future-oriented basis for tomorrow’s smart grid applications, which will help handle the increased feed-in of renewables-based power, Siemens claimed.

The core tasks, according to Siemens, include remote reading and management of all meters in a supply area. Gas and water meters communicate bidirectionally via smart Siemens AMIS meters. It added that existing ripple control systems can be replaced with the new technology. Furthermore, utilities can utilise the system to record network parameters such as over and undervoltage, short-term and long-term failures, and power quality indicators from the medium-voltage network and to the end-customers, the announcement said.

It further claimed that network operation, as a whole, can, thus, be optimised on the basis of detailed information, such as, ground-fault and short-circuit displays, and measurable asset indicators. Additional services, such as gas and water metering are also possible, along with a range of solution modules that support network-wide process automation. This, said the announcement, includes integration of the meters, data concentrators and transaction servers of the AMIS automated metering and information system, and the linking up of utility IT systems to the Energy IP data hub – the metering management system of Siemens’ partner eMeter. Solutions for telecontrol of the low-voltage network, monitoring of network quality and support for mass installation of electronic meters complement the portfolio, it added.

According to the announcement, at Metering Europe in Vienna, a demonstration showed how Siemens integrates the Energy IP metering management system as part of a holistic smart metering solution via the SAP-certified MDUS (Meter Data Unification and Synchronisation) interface into an existing corporate IT environment. The announcement further explained that it applied both to Siemens AMIS smart meters and to the meters supplied by other manufacturers.

Siemens added that with its network planning tool Sincal, it was able to demonstrate in Vienna, how the metering management system can use cumulative measured data, instead of statistically postulated consumption data as real consumer load profiles for network planning and simulation in order to provide a more precise basis for computations. The use of actual consumption data will become even more necessary, the more the renewables-based power fed into the grid and increased amounts of energy are drawn at night, for example, to charge electric vehicles, explained Siemens.

A round-up on the recently concluded Chillventa in Germany

Chillventa 2010, the International Trade Fair for Refrigeration, which took place from October 13 to 15 in Nürnberg, Germany, drew nearly 900 exhibitors, nearly 63% of them international.

“The increase in the number of exhibitors to currently 880 international companies shows me how important our exhibition is for the international refrigeration, air conditioning, ventilation and heat pump sectors,” said Gabriele Hannwacker, the Exhibition Director of the event. “I am also pleased about the large international share of exhibitors.

The Cleanroom Village

A highlight of this year’s event was the Cleanroom Village – a highly specialised presentation of cleanroom technology. Walter Ritz, Senior Consultant Pharma, TÜV SÜD Cleancert, said: “The Cleanroom Village is an ideal extension to the existing range of products at Chillventa and gives visitors and exhibiting companies a special platform for dialogue. I see the Cleanroom Village as a cross-industry expert forum that also appeals to the broad base of Chillventa visitors as well as to the cleanroom professionals,”

Running parallel to the Village was a forum, where top cleanroom experts gave presentations and discussed current issues. The forum focused on cleanroom fundamentals, current technology trends, certification requirements and necessary measures for staff training.

Energy efficiency and high-tech

The Industrial Heat Pump Village, in Hall 1 focused on heat pumps for the second time. Here, 19 companies presented their products and solutions for heat pumps.

Congressing

Another key attraction at the event was the Chillventa Congressing programme, which ran parallel to the exhibition. It supplied information covering all segments of refrigeration, air conditioning, ventilation and heat pumps.

Chillventa Congressing started the day before the exhibition with an IEA-HPP workshop on Industrial Heat Pumps and the established ASERCOM + EPEE Symposium. The symposium on “Air-Air Heat Pumps for Heating and Air Conditioning of Commercial Property” was organised under the technical direction of Prof Franzke of ILK Dresden. ESaK – the European Academy of Refrigeration and Air Conditioning – started a new approach with its “Presentation by Trainees”, at which students presented their study projects and theses. Due to current developments in refrigerants, an additional symposium on “Refrigerant – Sustainable Future” was included, which allowed an up-to-the-minute overall survey of activities concerning new refrigerants. All the major manufacturers were involved in this event, which was under the technical direction of Prof Ullrich Hesse from the Bitzer Endowed Professorship for Refrigeration and Compressor Technology at Dresden University. ASHRAE rounded off the day before Chillventa with a workshop on “Reducing Energy Use in Data Centres”.

On October 14, eurammon offered its series of presentations on “Applications with Natural Refrigerants – Country Situation and Experiences”, with four lectures in English.

Visitors to the event also had the opportunity to source extensive information at forums on refrigeration, air conditioning, ventilation, heat pumps and cleanrooms. The forums focused on topics, such as energy efficiency of refrigeration plants and components, industrial refrigeration, supermarket refrigeration, refrigerant development, energy efficiency, regulations, power control, energy-optimised components and solutions for phasing out R22.

Claims Vestolen range is sustainable and cost effective material for pressure pipe applications

According to an announcement, SABIC, manufacturer of plastics, polyethylenes, polypropylenes and chemical products, introduced its Vestolen range, termed ‘A RELY’ portfolio, at the Plastic Pipes XV Conference in Vancouver, Canada. SABIC described it as a bimodal high-density polyethylene (HDPE) material for pressure pipe applications, and claimed that Vestolen offers converters energy savings and enables environmentally responsible pipe installation. The term ‘RELY’ referred to the material’s reliability, which is critical for transporting potable water, gas and other liquids, explained SABIC.

It stated that the first two grades in the Vestolen A RELY portfolio are Vestolen A RELY 5924R and Vestolen A RELY 5922R, and elucidated that one is designed for low sagging and the other is engineered for high resistance to slow crack growth. It claimed that this would enable developers and contractors to select trenchless pipe installation, such as guided boring and horizontal directional drilling, which reduce impact on the environment. The materials are classified as PE100 grades, demonstrating compliance with the highest industry standards for HDPE pressure pipe, SABIC added.

According to the announcement, the company also presented a new strain hardening method for evaluating the slow crack growth resistance behaviour of HDPE. The method avoids the use of detergents that can pose an environmental hazard and also avoids the use of drinking water, the manufacturer claimed.

“Our new SABIC Vestolen A RELY products in combination with the strain hardening method – that measures their performance – are key deliverables in SABIC’s global strategy to supply the pressure pipe industry with breakthrough technologies,” said Jean Engels, Business Manager, HDPE SABIC. “SABIC takes great pride in proactively developing materials and methodologies that meet current and emerging industry needs, particularly in the areas of sustainability and cost effectiveness. We also welcome new partners who can help us drive development of new pipe solutions utilising our high-performance HDPE materials and extensive technological resources and expertise,” he added.

As per the announcement, Vestolen A RELY 5924R and Vestolen A RELY 5922R are now available globally, and additional grades within the product line are due for release in the near future.

Will supply products to infrastructure projects

Systemair, the Sweden-based company, has announced that it has received three orders valued at a total of approximately SEK 14 million for the supply of its products to major infrastructure projects in India. The first project is Kolkata Airport, one of India’s largest, to which Systemair will deliver about SEK five million worth of ventilation products, beginning in November, said the announcement.

The other two projects are Delhi Metro Rail Cooperation and Delhi Airport Metro Express Line, where the company will be delivering about SEK nine million worth of ventilation products. According to Systemair, the Delhi projects now in its kitty, are linked to the company’s involvement at Delhi Airport last year, which came as its first breakthrough in India.

Commenting on the orders, Gerald Engström, CEO, Systemair, said: “There are a number of major infrastructure projects in India, where we see a great potential to contribute and deliver our products. These are three prestigious orders that clearly strengthen our position in India.”

Engineered solution provides low-temperature application for ATK and NASA

Aggreko, which deals in rental power, cooling, heating and oil-free compressed air, announced that it is working with Alliant Techsystems (ATK) to test Development Motor-2 (DM-2), NASA’s second fully-developed Ares five-segment solid rocket motor. Aggreko’s low temperature chillers were used to execute the DM-2 ‘cold motor’ test – supporting ATK’s objective to meet NASA’s specification to cool the motor to 40°F to measure solid rocket motor performance at low temperature and verify design requirements of new materials, the announcement added.

According to Aggreko,the temperature of DM-2 was controlled by the atmospheric conditions within the removable building housing, the test motor. It explained that to achieve this scope of work in a controlled and repeatable manner, Aggreko process engineers and temperature control experts used specialised temporary utility equipment to cool the structure to target temperatures of 20°F. It added that its engineered solution for the cold motor test consisted of temporary generators to power the system of low-temperature chillers; specially designed low-temperature air handlers; a customised air conditioning duct system; and a suite of temperature control and electrical distribution equipment.

Describing the operation, Aggreko claimed that it designed a first-of-its-kind low-temperature air handler configuration to manage climate control for the mobile building – three stacks of two air handler units with a custom-made defrost unit. One of the air handlers drew air from inside the building, cooled it to 20°F, then recycled it into the building, while the remaining unit was on standby or defrost mode, enabling continuous cooling of air, Aggreko explained. A seventh air handler was installed to provide fresh air and positively pressurise the mobile building to eliminate infiltration of warm, moist air.

Aggreko said that prior to the live test, it detached the equipment from the building, and the structure was rolled away, and that it continued to cool the rocket motor section joints with a custom air conditioning duct system up to an hour before the rocket was fired.

“This project was unique due to its many special requirements,” said Steven Bukoski, Project manager for Aggreko Process Services, a process engineering group within Aggreko. “Aggreko’s specialised, large-capacity portable equipment and skilled technicians were critical factors in successfully achieving freezing temperatures under challenging environmental conditions, such as hot summer temperatures, cooling 1.6 million pounds of propellant, and working with a movable structure.”

“Reliable equipment and working closely with ATK on all critical issues enabled our team to meet NASA’s temperature cooling requirement and support this important milestone for NASA’s space flight programme,” he added.