01 MR Lee Eng Lock - Neeconf

Industrial Energy Efficiency:
Fast, Simple, Proven, what's holding us

back?
Climate Solutions
Asia Pacific
24 May 2011
The Journey Begins ………….
‹#› Insert Footer
1983—Condenser water flow study
• 2 x 480 RT screw chillers + 2 x 120 RT reciprocating

• Design condenser flows 1,440 usgpm & 360 usgpm
• Magnetic flowmeter on main riser pipe
• 480 RT chiller flows ~ 1400usgpm
• 120 RT chiller flows ~ 1300 usgpm
• Same flowmeter on riser is reading both flows so
accuracy not in question
• ―There are 3 kinds of people—those who make
things happen, those who watch things happen,
and those who don’t know what is going on‖

Engineering Education……
• Education is not the filling of a pail, but the lighting of a fire.

• William Butler Yeats
• “In Germany when an engineer says he has 25 years of

experience it means he spent one year making mistakes and
then 24 years repeating them” …………….Professor Kratel
• Education is the most powerful weapon which you can use to

change the world.
Nelson Mandela

STM Factory, AMK
Chiller retrofit energy project - 1.53 years pay back = ROI > 50%
FREE PHASE : One chiller operation status
Analyse manufacturing curves vs
real time operating points
Real time operating point
Manufacturing curves
Deletion of triple valve of PMP21-202 during 8Mar2002-
16Mar2002
Install new 20”

check valve with
low friction check-
valveand change the
pipe to 20 “
Deletion of 14”
TDV
AHU ENERGY RETROFIT
CASE STUDY 1. ST Microelectronics Pte Ltd
Replacement of two Outside Air AHU

Year of completion: 2000
SUMMARY:
Savings of 140 kW
or 80% on
operating cost

AHU ENERGY RETROFIT
CASE STUDY 1. ST Microelectronics Pte Ltd

Executive Summary
OLD and NEW AHU PERFORMANCE
# AHU Parameter (100% fresh air): Unit OLD AHU NEW AHU
1 Total cooling capacity Ton refrigerant 340 354
15-pre-cool,
2 Chilled water supply temperature Degree C 6 6-final cooling
3 Chilled water temperature rise Degree C 5.5 11
4 Fan power consumption KW 35 7
5 Chiller power consumption KW 212 170
6 AHU efficiency KW/Ton 0.1 0.02
SAVINGS
# Savings (for 2 units): kW % $Sin/Year
1 Fan power consumption 56 80 72,800
2 Chiller power consumption 84 20 109,200
3 Total 140 182,000
‹#›Payback
Insert Footer
period of investments 1.9 years
―Good‖ ideas to save energy…..

Measured by SISIR and others……

Perpetual Motion Machine
1. Exhaust Fan Efficiency = 70%

2. Exhaust Fan Motor Efficiency = 85%
3. Windmill Fan Efficiency = 60%
4. Windmill Generator Efficiency= 80%
5. Total Efficiency = 0.7 x 0.85 x 0.6 x 0.8 = 29%
6. The Best Way to make a small fortune is start
with a BIG one

Labor is a big part of costs for chip packagers. In Muntinlupa City, just outside
Manila, Pilipinas has over 6,000 employees. But given the need for huge clean
rooms with oceans of filtered air, energy costs are high. Two years ago the
company called in a Singapore engineering firm, Supersymmetry Services,
and asked it how to reduce the electric bill in the 689,000-square-foot Muntinlupa
plant as well as in a new facility planned not far away.
Supersymmetry was founded in 1988 by Lee Eng Lock, a Singapore-born

British-educated engineer with a growing international reputation for an
iconoclastic approach to the design and construction of HVAC systems,
particularly for electronics-plant clean rooms. Lee says there is "no special magic"
needed to cut HVAC costs, just a "return to basic value-for-money thinking,
careful measurement and analysis, openness to new ideas, and willingness to do
hard work." He contends that the reasons companies settle for less efficient
HVAC systems, at least in Asia, are "fear of loss of face, payola, very nice
entertainment in Hawaii, karaoke lounges, golf, total disinterest, vested
interest...."
In Manila, Lee started with the easy ones: upgrading the lighting, turning off the
office air conditioning at night, replacing screw-type air compressors with high-
Turn Down the efficiency centrifugal units. Then he rebuilt or tuned up the air-conditioning and
handling system. Ed Ornela, the company's corporate engineering director in the
Energy/Tune Up the Profits Philippines, calculates that the new air compressors cut the annual electric bill by
$580,000; a new chiller and changes in chiller operation saved another $620,000;
and other improvements lopped off $919,000. Amkor/Anan's electricity bill
Only a third of U.S. manufacturers are seriously scrutinizing actually went up, from $7.2 million in 1995 to $8.5 million in 1997, as chip output
doubled. But the power cost per chip, adjusted for chip size, tumbled by 37%.
energy usage, where savings in five areas can move billions
to the bottom line. Examples like these ought to inspire companies that have paid little attention to
their energy bills. A lot of waste, ironically, can be found in some U.S.
semiconductor plants that feed work to companies like Amkor. A chip plant's
Philip Siekman electricity bill can easily hit $2 million a month. That concerns utilities and
governments, particularly in the Pacific Northwest. The Northwest Power
Planning Council, made up of representatives of four of the region's state
governments, sponsored a workshop where Lee Eng Lock showed how to reduce
HVAC power requirements in clean rooms from a current 1.2 kilowatts to two
kilowatts per ton of cooling capacity to what he says is an achievable 0.6 kilowatt
‹#› Insert Footer to 0.7 kilowatt per ton.
Power cost per chip produced, saved
37%.
In terms of $ - savings of more than
US$2 million annually Removal of secondary pumps
Installation of high efficiency chillers
Installation of magnetic flow meters and inverters

Energy savings of 90% of total electricity Air
Handling Unit electricity use with additional 180
Inefficient Design is RT on top of original design tonnage. Production
replaced by efficient and room specs met without fail! RM 350,000 per
simple design with proper annum savings on RM 900,000 investment!
controls

Western Digital Factory
Using high efficient axial

fan for re-circulation air.
Testing the roof with

white reflective paint.
Energy Project of the Year - International, 1996
Unit cost comparison:

Sanyo Factory at Gifu
ENERGY USAGE
Total electrical energy= 82,194,039 kWh
Total energy bill
Total energy used in G2+G3 plant

=Electrical + LPG
=USD 8 millions + USD 1.61 millions
Largest Solar Array in the world for Sanyo Wafer Fab
=USD 9.61 million
12 Recommendations to save US$5.4 million in utility cost.

Recommendation 1 : Free Cooling and Free Heating
• Energy Saving (kWh) per year 60,907,538 kWh (LPG fuel energy)
• Utility bill saving per year USD 1,540,636 per year
• Investment USD 5,000,000
• Simple Payback 3.24 Years
• Simple ROI 30.81 %
Recommendation 2 : Cogen Plant
‫ڵ‬Energy Saving (kWh) per year (Steam energy gain) 43,800,000 kWh LPG saving
‫ڵ‬Energy Saving (kWh) per year*(transmission loss 3%) 2,628,000 kWh Electrical saving
‫ڵ‬Utility bill saving per year USD 5,220,000Per year
‫ڵ‬Investment USD25,000,000
‫ڵ‬Simple Payback 4.78 Years
‫ڵ‬Simple ROI 20.92 %

Energy Efficiency Project
for Sony Semiconductor
Capital Cost 4 Billion Yen
Energy Savings 25% of Bill
Payback within 3 Years

Optimising Fluid Movement
1. >250 Vacuum Pumps
• Presently using 13C Cooling

water, >150 kW pumps
• Constant water flow
• Specs is <30C inlet water, <40C

outlet water
• Convert to variable temperature,

variable flow
• Savings on chiller + Pumps >170 kW.

Insert subtitle here

Energy Audit/Workshop
for Shell Oil Refinery at Fredericia, Denmark
EDS Newcastle data centre—reverse
clean room…March2008
--97% annual free-cooling


Low quality sensors lead to wrong results
• xxxxxxxxxxxxxxxxxx
Site Seagate City
• xxxxxxxxxxxxxxxxxx
Subj Chiller Performances per Energy Audit data by Others
Description Ch 1 2 3 4 5 6 7
CHW Set Temp 5.5 5.5 5.5 - 5.5
CHWS T ( degC ) 5.8 5.8 6.3 6.1 5.8
CHWR T ( degC ) 11.2 10.8 11.1 10.9 11.3
dT 5.4 5.0 4.8 4.8 5.5
Design 30.5 30.5 30.5 30.5 30.5

CWS Temp ( degC ) 29.7 29.6 30.1 30.1 30.5
CWR Temp ( degC ) 33.8 34.2 34.6 33.8 35.3
dT 4.1 4.6 4.5 3.7 4.8
Design kW 730.0 730.0 730.0 730.0 730.0

% RLA Avg 87.0 90.3 98.0 91.7 93.7
A 85.0 89.0 95.0 89.0 88.0
B 90.0 93.0 100.0 94.0 100.0
C 86.0 89.0 99.0 92.0 93.0
Approach Temp Cond 1.0 0.9 0.9 0.0 0.4

Approach Temp Evap 1.5 2.3 2.0 2.1 1.3
IGV position % 100 100 97.1 100 86.9

Remark Limit by Vane stop Lim by I lim by I -
Flow CHW Lo 2960 2500 3150 3100 3700

Flow CHW Hi 3500 3000 3650 3350 3700
Design RTon 1,250 1,250 1,250 1,250 1,250

RTon Lo 1,199 938 1,134 1,116 1,526
RTon Hi 1,418 1,125 1,314 1,206 1,526
RTon Average measured 1,308 1,031 1,224 1,161 1,526

RTon Average at 100% 1,504 1,142 1,249 1,267 1,629
Design kW/Ton 0.58 0.58 0.58 0.58 0.58

Efficiency Lo 0.53 0.70 0.63 0.60 0.45 Chiller efficiency too
Efficiency Hi 0.45 0.59 0.54 0.55 0.45
Efficiency Avg 0.49 0.64 0.59 0.58 0.45 good to be true !!
Filling in other trended data revealed questionable results

‹#› Insert
NoteFooter
:
Per Others Data, all Chillers are peformance within design or better !!
Typical overkill is educational…..
Cooling Tower Cooling Tower Cooling Tower
CWP CHWP CWP CHWP CWP CHWP
Chiller 300 RT Chiller 300 RT Chiller 300 RT
Transformer 1,000 KVA Transformer 1,000 KVA Transformer 1,000 KVA

Total Electrical: 3000KVA
Total Cooling: 900RT (Actual Use= 250RT)
‹#› Insert Footer Actual Use: 350KVA (Best Practice= 200KVA)
Comparison of System kW (Before & After)
System kW
System kW (Before – 25th Nov to 19th Dec 2006)
Savings in kW
System kW (After – 1st May 2007 to 14th May 2006)
‹#› Insert Footer Chilled Water Ton

Singapore Post Centre
System Efficiency (kW/Ton) – Daily/Weekly Analysis
35,000
For the week: 15-June-2007 to 21-June 2007 0.6000
0.5900
30,000
0.5800
25,000 0.5700
0.5600
20,000
Ton-hr
0.5500 kW-hr
kW/ton
15,000
0.5753 kW/Ton
0.5758 kW/Ton
0.5840 kW/Ton
0.5830 kW/Ton
0.5688 kW/Ton
0.5670 kW/Ton
0.5745 kW/Ton
0.5400
10,000 0.5300
0.5200
5,000
0.5100
0 0.5000
Fri Sat Sun Mon Tue Wed Thu
15-Jun-07 16-Jun-07 17-Jun-07 18-Jun-07 19-Jun-07 20-Jun-07 21-Jun-07 Average
Ton-hr 28,652 20,811 15,133 28,707 28,071 27,379 27,404 25,165
kW-hr 16,483 11,982 8,838 16,736 15,968 15,525 15,744 14,468
kW/ton 0.5753 0.5758 0.5840 0.5830 0.5688 0.5670 0.5745 0.5755
System kW/RT SingPost 18~20 Feb 2008

Galen Chiller Plant
Retrofit

Action on HFC Gases "Low Hanging Fruit"
Opportunity to Combat Climate Change
• Nairobi, 22 June 2009 – A scientific paper, highlighting the need

to
accelerate action over a group of gases known as
Hydrofluorocarbons (HFCs) as part of the climate change
agenda, was today welcomed by the head of the UN
Environment Programme (UNEP).
The findings, by an international team of researchers are
published in
the Proceeedings of the National Academy of Sciences…….
Under a scenario where carbon dioxide emissions are pegged

to 450 parts per million HFCs could equal nine Gigatonnes -
equivalent to around 45 per cent of total C02 emissions - by
2050 if their growth is unchecked.

JARN interview with USEPA’s Director
Dr Stephen Anderson
“The cost of the refrigerant is a small part of owning an air conditioner or a refrigerator. The biggest part is the
purchase price and the electricity. So, I think that the refrigerant costs are of minor significance.”
So far, there’s no essential use for HCFCs because the phase-out comes many years into the future. Most people
believe there will be an essential use exemption for HCFC. And if that were true, and the HCFC-123 building air
conditioners retained their competitive advantage for high energy efficiency, then they probably would get that
exemption. So you could keep using 123 until a better refrigerant comes. But here’s the more important question,
why would someone believe that HFC-134a will be in the market longer than HCFC-123?
There is no plan to further accelerate the HCFC phase-out, but there is every intention to accelerate the HFC-134a
phase down. So HFC-134a may be gone from chillers before HCFC-123. Today when you go to buy, and you ask
the question, which refrigerant will last the longest in the market, I don’t think it’s HFC-134a. HFC-1234yf should
work anywhere HFC-134a is working today. Both HCFC-123 and HFC-134a are in regulatory jeopardy, but the
difference is that HCFC-123 gets higher energy efficiency. For large chillers, it’s the top-runner.
HCFC-123 is currently the best in the market. With 134a under phase-out worldwide
for cars, stationary is next. It’s exciting!
Nov2008



Ansari X prize --- Space Flight

IDEAS SOUGHT FOR BETTER
DESALINATION – Aug 2007
Business Times, Singapore
• The Environment and Water Resources Ministry is looking for

better ways to make clean water out of seawater.
• Its Environment and Water Industry Development Council is
asking all local and overseas institutes of higher learning, research
institutes and private sector companies to submit proposals for
technologies which can desalinate seawater using a total energy
consumption of not more than 1.5 kWh per m3 of water produced -
less than half the energy now used by other technologies.
• The closing date is Nov 2. For more information. go to
www.mewr.gov.sg/ewi .

Cheaper way found to make sea water
drinkable—Straits Times, 24June2008
…...Siemens Water Technologies team yesterday bagged a

S$4 million grant from the Environment and Water Industry
Development Council (EWI)…. used electricity instead of
high pressure or heat to remove salt from sea water, and
produced a cubic metre of pure drinking water on 1.5
kilowatt-hours (kWh) of power.
.
….PUB technology director Harry Seah described the novel
approach as one which 'blows convention away'.
….Prof Lui …. 'This is what we call disruptive technology - and
it's exactly what we're looking for.'
News of this new technology is a prelude to the cutting-edge
technologies that will be on show at the Singapore
International Water Week, which officially opens today.

Negawatt - X Prizes
• First High Temp Chiller Plant to achieve 0.40 kW/RT

• First Low Temp Chiller Plant to achieve 0.50 kW/RT
• First low cost M&V hardware/software product for
chiller plant to achieve ARI-550 accuracy or better
• First Lighting System to achieve 200 Lumens/Watt
• First HVAC system to achieve 0.65 kW/RT
• First property developer to allow real time access to
various properties types for MEP systems, online
documentation, etc setting high standards

Latest NEA guidelines for energy
audits in Singapore—June 2009
– Chilled water plant system performance

• System performance measurement error shall not exceed ±5%.
This implies the use of high accuracy thermometry and
calorimetry.
• Detailed method statement explaining how the required degree
of accuracy was achieved with the instruments and data
acquisition hardware employed.
• Data required to establish system performance must be
sampled and acquired simultaneously and continuously for a
minimum of 1 week at one-minute intervals.

Latest NEA guidelines for energy
audits in Singapore—June 2009
• The appendices should include:

• Schematics and layout drawings of facility or building audited
• Details of instrumentation used – parameters monitored and
duration of monitoring for each parameter
• Data plots of performance of systems or equipment audited
• Energy efficiency of major equipment compared against
industrial benchmarks
• Measurement and verification (M&V) plan for monitoring and
verifying energy savings for each of the recommendations
• CD-ROM containing the raw measurement data

‹#› Insert Footer Performance metric : 9.69 secs/100 meters
Making Energy Efficiency Accountable
Right now there is no off-the-shelf delivery

process in place to develop truly effective energy
efficiency improvements with long term
performance assurance.
Thomas Hartman, P E
The Hartman Company
June 2007,
automatedbuildings.com

Ashrae--Chiller Plant Efficiency
New Technology High-efficiency Conventional Chiller Plants with

Older Chiller
All-Variable Speed Optimized Code Based Correctable Design or
Plants
Chiller Plants Chiller Plants Chiller Plants Operational Problems
EXCELLENT GOOD FAIR NEEDS IMPROVEMENT
kW/ton 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

C.O.P. (7.0) (5.9) (5.0) (4.4) (3.9) (3.5) (3.2) (2.9)
AVERAGE ANNUAL CHILLER PLANT EFFICIENCY IN KW/TON (C.O.P.)
(Input energy includes chillers, condenser pumps, tower fans and chilled water pumping)
Based on electrically driven centrifugal chiller plants in comfort conditioning applications with
42F (5.6C) nominal chilled water supply temperature and open cooling towers sized for 85F
(29.4C) maximum entering condenser water temperature and 20% excess capacity.
Local Climate adjustment for North American climates is +/- 0.05 kW/ton

Simple Guide to retrofit success
• Ask for 1 minute trend data for chiller plant parameter

eg tons, kw/ton, flow rates, kw, pressures,
temperatures, ambient temp and wet bulbs for 3
months in spreadsheet format
• Ask for previous performance contract examples with
bank guarantees
• Ask for online internet access to previous projects
• Ask for ARI-550 accuracy of +-5% for chiller plant
efficiency, using as guides ASHRAE 14P & 22.
• Ask for 0.60 kW/RT or better for chiller plant

The Evolution of truth…
• All truth passes through three stages.

• First, it is ridiculed.
• Second, it is violently opposed.
• Third, it is accepted as being self-evident.
–
– Arthur Schopenhauer
German philosopher (1788 - 1860)

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Industrial Energy Efficiency:

Fast, Simple, Proven, what's holding us

• 2 x 480 RT screw chillers + 2 x 120 RT reciprocating

‹#› Insert Footer

• Education is not the filling of a pail, but the lighting of a fire.

• “In Germany when an engineer says he has 25 years of

• Education is the most powerful weapon which you can use to

‹#› Insert Footer

Real time operating point

Install new 20”

CASE STUDY 1. ST Microelectronics Pte Ltd

Replacement of two Outside Air AHU

‹#› Insert Footer

CASE STUDY 1. ST Microelectronics Pte Ltd

‹#› Insert Footer

‹#› Insert Footer

1. Exhaust Fan Efficiency = 70%

‹#› Insert Footer

Supersymmetry was founded in 1988 by Lee Eng Lock, a Singapore-born

Installation of high efficiency chillers

Installation of magnetic flow meters and inverters

‹#› Insert Footer

‹#› Insert Footer

Using high efficient axial

Testing the roof with

Unit cost comparison:

‹#› Insert Footer

Total energy bill

Total energy used in G2+G3 plant

12 Recommendations to save US$5.4 million in utility cost.

Recommendation 2 : Cogen Plant

‫ڵ‬Utility bill saving per year USD 5,220,000Per year

‫ڵ‬Simple Payback 4.78 Years

‫ڵ‬Simple ROI 20.92 %

‹#› Insert Footer

Capital Cost 4 Billion Yen

Energy Savings 25% of Bill

Payback within 3 Years

‹#› Insert Footer

1. >250 Vacuum Pumps

• Presently using 13C Cooling

• Constant water flow

• Specs is <30C inlet water, <40C

• Convert to variable temperature,

• Savings on chiller + Pumps >170 kW.

‹#› Insert Footer

‹#› Insert Footer

‹#› Insert Footer

‹#› Insert Footer

Subj Chiller Performances per Energy Audit data by Others

Design 30.5 30.5 30.5 30.5 30.5

Design kW 730.0 730.0 730.0 730.0 730.0

Approach Temp Cond 1.0 0.9 0.9 0.0 0.4

IGV position % 100 100 97.1 100 86.9

Flow CHW Lo 2960 2500 3150 3100 3700

Design RTon 1,250 1,250 1,250 1,250 1,250

RTon Average measured 1,308 1,031 1,224 1,161 1,526

Design kW/Ton 0.58 0.58 0.58 0.58 0.58