Report_Chiller(by Sayan Roy)

Report on Industrial Training
At
IFB Industries Limited
14, Taratala Road, Kolkata-700088

2
Report
On
Study and Performance
Analysis of
Chilling Plant
Submitted By
Sayan Roy
Department of Mechanical Engineering (3rd
year)
Future Institute of Engineering & Management
Training Period: 23/12/2014 - 15/1/2015
Under the guidance of:
Mr. Soumen Ghosh (Head), Mr. Suvra Bose,
Mr. Sumanta Panja, Mr. Arijit Boral
(Maintenance Department)
IFB Industries Ltd., Taratala

3
Sl. No.
Contents Page No.
1. Acknowledgement 4
2. Introduction 5-8
3. IFB Profile 9
4. Process of the Plant 10
5. Fine Blanking Technology 11 -13
6. Fine Blanking Process 14-16
7. Manufactured Products 17-18
8. Chilling plant 19-20
9. Refrigeration Systems 21-23
10. Chilling Plant Components 24-28
11. IFB Chilling plants 29-32
12. Observation Data Sheets 33-38
13. Performance Terminology & Measurement 39-40
14. Sample Calculation 41-42
15. Performance Analysis 43-45
16. Energy Saving Opportunity 46-47
17. Conclusion 48
18. References 49

4
Acknowledgement
West Bengal University of Technology (WBUT) curriculum
includes industrial training which can benefit the student in many
ways to gather practical knowledge and to be aware of industry
environment. I am very obliged to the management and the
maintenance department of IFB INDUSTRIES LTD, Taratala
for giving me an opportunity to do my industrial training there.
I want to express my gratitude and sincere thanks to Mr.
Shantanu Chakraborty(Head of Quality Assurance Dept.),Mr.
Soumen Ghosh (Head of Maintenance Department), Mr. Suvra
Bose, Mr.Sumanta Panja, Mr Arijit Boral, ,Arindam Bose, Mr.
Koushik Sinha (HR manager) and all officials who have helped
us to undertake and complete my project on industrial training.
I also thank all employees of IFB who helped me in our training
directly or indirectly and it is because of them I completed my
project successfully.

5
Introduction
The fine blanking process was patented for the first time in 1923 in
Germany. The original idea was to apply a counter pressure force while
blanking to prevent the edges from breaking and causing them to shear
over the total thickness of the material. This technology was initially
employed mainly in the office machine industry and the watch and clock
industry.
During the early years, fine blanking dealt mainly with materials from 1
to 3 mm. Today more than 60% of fine blanked parts are used in the
automotive industry with thicknesses of up to 19 mm.
Considerable technological breakthroughs have been made in tooling,
presses and materials for fine blanking in recent years. Companies are
considering fine blanking at the design stage, taking full advantage of its
capabilities.
Today, the fine blanking method of manufacturing has become a
necessity in several major industrial sectors. Although first initiated in
Europe, fine blanking has taken an important place particularly in the
Japanese and North American automotive industry, replacing many of
the more expensive manufacturing options.
[1]

6
IFB: Company Overview
IFB Industries, originally known as Indian Fine Blanks, started its
operations in India during 1974 in collaboration with Switzerland’s
Hienrich Schmid AG. The product range includes fine blanked
components, tools and related machine tools like straighteners, de-
coilers, strip loaders and others.
The engineering divisions of the company are located at Kolkata
and Bangalore. The Bangalore unit, apart from fine blanked
components, manufactures motors for white goods as well as automotive
applications. It also has an ultra-modern plant under subsidiary
European Fine Blanking at Wrexham, Wales, and UK.
It had recently acquired a microwave oven plant at Bhopal, which is
being upgraded for increased production of better microwave ovens and
plans to start a new line in dish-washers.
The Bangalore and Kolkata works are ISO 9001 and QS 9000 certified
by TUV SDI. The Bangalore unit has been certified for TS 16949 by
TUV SDI.
The launch of fully automatic washing machines in 1990, jointly
with Bosch, Germany, marked IFB's entry into the white goods sector.
IFB is the premier Fine Blanker in India having Fine Blanking Presses,
with capacities ranging from 90T to 800T.
The company has excellent facilities for tool design and tool making
enabling it to meet up the expectations of all the automobile

7
manufacturers in the country as well as some overseas customers, by
supplying high quality fine blanking components on schedule.
Its philosophy is to deliver the parts in fully finished conditions at the
customers' delivery point. Its mission is to be an enabler to the customer
in design of the components during initial stage of product development
IFB has a research and development centre equipped with high-end
software’s like Solid modelling, CATIA, FEA and Mold Flow for the
design and analysis of various products. Besides it also has highly skilled
and experienced tool designers designing fine blanking parts and tools
to international standards.
The company’s international business division has become a recognized
Export House dealing in not only IFB's own products but also third-party
exports.
The company’s customers include Maruti Udyog, Ford India, Fiat India,
Toyota Kirloskar Motors, Lucas TVS, Brakes India, Autoliv India, Rane
TRW, IFB Automotive,
Germany’s Takata Petri, BorgWarner, Avtec and Bosch chassis.
Subsidiaries:
IFB, in collaboration with Germany’s RHW and Sweden’s Electrolux,
has two joint venture subsidiaries -- RHW India and RHW
Autoliv India -- to manufacture automotive seat recliners or seating
systems and safety equipment.
Latest Development:
The Committee of Directors of IFB Industries had recently allotted 68,
00,000 equity shares of Rs.10 (at par) to IFB Automotive, a promoter
group company. The promoters brought in above fund in line with the
direction of Board for Industrial and Financial Reconstruction (BIFR)
in the sanctioned scheme.

8
Automotive Sector:
Non-Automotive Sector:
[2]

9
IFB PROFILE
IFB INDUSTRIES LIMITED was founded in Kolkata in 1974 in
collaboration with Heinrich Schmidt AG of Switzerland by Mr. Bijon
Nag, a technocrat entrepreneur, having practical experience in fine
blanking in Germany and Switzerland for many years.
1. IFB is the Premier Fine Blanker in India having fine blanking
presses ranging in size from 90 to 1160 T.
2. Having factories in Kolkata and Bangalore the second unit was
established in 1988.
3. The company has total of 6 fine blanking presses in Kolkata,
capacity range from 90T to 650T.
4. The company has excellent facilities for tool making and tool
design enabling the company to meet up the expectation of all the
automobile manufacturer in the country as well as some overseas
customers, by supplying high quality fine blanking component on
schedule.
5. Quickest possible delivery :The company’s philosophy is to deliver
the parts in fully finished conditions at the customers’ delivery
point and thanks to the company’s innovative capability in post fine
blanking operations like grinding, CNC machining ,forming and
specialized techniques.
6. The Company’s Mission is to be an enabler to the customer in
design of the components during initial stage of product
development.
7. Support to the customers on technical problems.
8. Highest level of quality control.
9. Regular monitoring on customers’ satisfaction. [3]

10
Process of the Plant
Serial No. Process Name Location Machine
1. RAW MATERIAL
INSPECTION
IFB TARATALA MANUAL
2. FINE BLANKING IFB TARATALA BLANKING
PRESSES
3. HAND LINISHING
& FILING
VENDOR HAND LINISHING
M/C
4. STRESS
RELIEVING
IFB
GANGARAMPUR
TEMPERING
FURNACE
5. BARRELING IFB
GANGARAMPUR
VIBRO BARREL
6. BENDING VENDOR MECHANICAL
PRESS
7. PIERCING VENDOR MECHANICAL
PRESS
8. CSK ON ROLL
OVER & BURR
SIDE
VENDOR DRILLING M/C
9. FINAL
INSPECTION
IFB TARATALA MANUAL
10. OILING &
PACKAGING
IFB TARATALA STRAPPING M/C
[4]

11
Fine Blanking Technology
Blanking:
Blanking is a mechanical process of cutting, punching or shearing a piece
of metal into a desired shape. In other words we can define blanking as
metal fabrication process during which a metal work piece is removed
from the primary metal strip or sheet when it is punched. The material
that is removed is the new metal work piece or blank.
Application of Blanking:
Blanking process is widely used by electronic and micromechanical
industries to produce small and thin components in large production.
To take into little consideration the influence of strain rate and
temperature on precision blanking of thin sheet in copper alloy a thermo
elasto visco plastic modelling has been developed.
[5]
Fine Blanking
Fine blanking is a specialized type of blanking where there is no
fracture zone while shearing. This is achieved by compressing
the whole part and then an upper and lower punch extract the
blank. This allows the process to hold very tight tolerance and
perhaps eliminate secondary operation. Materials that can be
fine blanked include aluminium, brass, copper and carbon
alloy and stainless steel.

12
Application of Fine Blanking:
In today’s scenario, fine banking technology has created
exclusive positions in automobile industry for producing high
precision parts for engine, door clutch, window filters, and gear
box. The process is used in vehicles, textile machines, packing
machines, electronics and electrical equipment, sewing
machines, household appliances etc.
[6]
FINE BLANKING PROCESS
Blanking & Piercing
Blanking and piercing are shearing processes in which a punch and die are used
to modify webs. The tooling and processes are the same between the two, only
the terminology is different: in blanking the punched out piece is used and called
a blank; in piercing the punched out piece is scrap. The process for parts
manufactured simultaneously with both techniques is often termed 'pierce and
blank'. An alternative name of piercing is punching.
[7]

13
Difference between Fine Blanking & Blanking
Conventional Blanking Fine Blanking
Edges are sheared up to one-third of the
thickness the rest remaining fractured. .
Edges are 100% sheared and bright over
the entire thickness
Components get dished in blanking,
especially with material above 1.5 mm
thickness.
No deformation occurs in blanking even
up to a thickness of 14 mm, i.e.
component remains flat.
Not possible A wall thickness of 60% of the material
thickness can be achieved in the blank.
Practically impossible, especially in
the case of material thickness of over
1.5 mm
Hole diameter of even 60% of the
material thickness can be pierced to close
tolerances.
Practically impossible Hardness of the sheared edges can be
achieved up to 150-200% over the
original hardness, due to work hardening.
This gives better wear resistance and
avoids heat-treatment in some cases.
[8]

14
Fine Blanking Process
A typical fine blanking tool is a single station compound tool
for producing a finished part in one press stroke. The only one
additional operation needed is the removal of a slight burr.
Three forces act during fine blanking operation. They are –
1. Main force
2. Counter force
3. Vee ring force
The entire process is depicted step by step here:
Step 1:
This represents a simple sliding punch fine blanking tool making a round washer
with a hole at its centre.
Step 2:
This tool closes, pressure embeds impingement ring into stock. This prevents
material flowing away from the punch, ensuring a smooth, extruded end on the
punch. The ring is ‘v’ shaped as shown in the figure below and hence we it is also
called V ring

15
Step 3:
Blanking punch advances until the punch is fully sheared and resting in upper die
opening. In the same action the pierce punch provides a hole in the work piece.
Simultaneously, the counter punch pressure holds the part firmly against face of
the advancing blanking punch. This maintains flatness and enhances the sheared
edges, eliminating die break or edge fracture.
Step 4:
All forces are relaxed and the tool starts to open. The ram descends by gravity.
Step 5:
Blanking pressure reverses and the punch pulls back and the ejector pin pushes
out slag. Simultaneously raw material advances for the next cycle.

16
Step 6:
Counter pressure is reapplied pushing the part out of the die opening.
Step 7:
Air blasts or mechanical sweeps remove part and slug from the die area
Step 8:
The system is ready to start the next cycle
[9]
IFB, Taratala has six fine blanking presses –
1. Mori (FB 650 – FDE) 4. Mori ( FB 250-FDE)
2. Mori (FB 250 – FDE) 5. Mori ( FB 320-FDE)
3. Italian (500 Ton) 6. Heinrich Schmid ( 90 Ton

17
Manufactured Products
[10]
Different parts of a car made by fine blanking
Four Wheeler Components:
[11]

18
Two Wheeler Components:
[12]

19
Chilling Plant
A chilling plant involves a chiller which is a machine that removes heat from a
liquid via a vapour-compression or absorption refrigeration cycle. This liquid can
then be circulated through a heat exchanger to cool air or equipment as required.
As a necessary by-product, refrigeration creates waste heat that must be exhausted
to ambient or, for greater efficiency, recovered for heating purposes. Concerns in
design and selection of chillers include performance, efficiency, maintenance, and
product life cycle environmental impact.
[13]
General schematic procedure of a chilling plant
Use in industry:
In industrial application, chilled water or other liquid from the chiller is pumped
through process or laboratory equipment. Industrial chillers are used for controlled
cooling of products, mechanisms and factory machinery in a wide range of
industries. They are often used in the plastic industry in injection and blow
molding, metal working cutting oils, welding equipment, die-casting and machine
tooling, chemical processing, pharmaceutical formulation, food and beverage
processing, paper and cement processing, vacuum systems, X-ray diffraction,
power supplies and power generation stations, analytical equipment,
semiconductors, compressed air and gas cooling. They are also used to cool high-
heat specialized items such as MRI machines and lasers, and in hospitals, hotels
and campuses.
Chillers for industrial applications can be centralized, where a single chiller serves
multiple cooling needs, or decentralized where each application or machine has its
own chiller. Each approach has its advantages. It is also possible to have a
combination of both centralized and decentralized chillers, especially if the cooling
requirements are the same for some applications or points of use, but not all.

20
Decentralized chillers are usually small in size and cooling capacity, usually from
0.2 to 10 short tons (0.179 to 8.929 long tons; 0.181 to 9.072 t). Centralized chillers
generally have capacities ranging from ten tons to hundreds or thousands of tons.
Chilled water is used to cool and dehumidify air in mid- to large-size commercial,
industrial, and institutional (CII) facilities. Water chillers can be water-cooled, air-
cooled, or evaporatively cooled. Water-cooled chillers incorporate the use of
cooling towers which improve the chillers' thermodynamic effectiveness as
compared to air-cooled chillers. This is due to heat rejection at or near the air's
wet-bulb temperature rather than the higher, sometimes much higher, dry-bulb
temperature. Evaporatively cooled chillers offer higher efficiencies than air-cooled
chillers but lower than water-cooled chillers.
Water-cooled chillers are typically intended for indoor installation and operation,
and are cooled by a separate condenser water loop and connected to outdoor
cooling towers to expel heat to the atmosphere.
Air-cooled and evaporatively cooled chillers are intended for outdoor installation
and operation. Air-cooled machines are directly cooled by ambient air being
mechanically circulated directly through the machine's condenser coil to expel heat
to the atmosphere. Evaporatively cooled machines are similar, except they
implement a mist of water over the condenser coil to aid in condenser cooling,
making the machine more efficient than a traditional air-cooled machine. No
remote cooling tower is typically required with either of these types of packaged
air-cooled or evaporatively cooled chillers.
Industrial chiller selection
Important specifications to consider when searching for industrial chillers include
the total life cycle cost, the power source, chiller IP rating, chiller cooling capacity,
evaporator capacity, evaporator material, evaporator type, condenser material,
condenser capacity, ambient temperature, motor fan type, noise level, number of
compressors, type of compressor, number of fridge circuits, coolant requirements,
fluid discharge temperature, and COP (the ratio between the cooling capacity in
TR to the energy consumed by the whole chiller in KW). For medium to large
chillers this should range from 3.5 to 7.0, with higher values meaning higher
efficiency. Chiller efficiency is often specified in kilowatts per refrigeration ton
(kW/TR).If the cold water temperature is lower than −5 °C, then a special pump
needs to be used to be able to pump the high concentrations of ethylene glycol.
Other important specifications include the internal water tank size and materials
and full load current. Control panel features that should be considered when
selecting between industrial chillers include the local control panel, remote control
panel, fault indicators, temperature indicators, and pressure indicators.

21
Refrigeration Systems
o Small capacity modular units of direct expansion type similar to
domestic refrigerators, small capacity refrigeration units.
o Centralized chilled water plants with chilled water as a secondary
coolant for temperature range over 5°C typically. They can also be
used for ice bank formation.
o Brine plants, which use brines as lower temperature, secondary
coolant, for typically sub-zero temperature applications, which
come as modular unit capacities as well as large centralized plant
capacities.
o The plant capacities up to 50 TR are usually considered as small
capacity, 50 – 250 TR as medium capacity and over 250 TR as
large capacity units.
Two principle types of refrigeration plants found in industrial use are:
 Vapour Compression Refrigeration (VCR)
 Vapour Absorption Refrigeration (VAR).
VCR uses mechanical energy as the driving force for refrigeration, while VAR uses
thermal energy as the driving force for refrigeration.
Vapour Compression Refrigeration
Heat flows naturally from a hot to a colder body. In refrigeration system the
opposite must occur i.e. heat flows from a cold to a hotter body. This is achieved
by using a substance called a refrigerant, which absorbs heat and hence boils or
evaporates at a low pressure to form a gas. This gas is then compressed to a higher
pressure, such that it transfers the heat it has gained to ambient air or water and
turns back (condenses) into a liquid. In this way heat is absorbed, or removed, from
a low temperature source and transferred to a higher temperature source. The
refrigeration cycle can be broken down into the following stages (see Figure 4.2):
1 – 2: Low pressure liquid refrigerant in the evaporator absorbs heat from its
surroundings, usually air, water or some other process liquid. During this process
it changes its state from a liquid to a gas, and at the evaporator exit is slightly
superheated.

22
[14]
2 – 3: The superheated vapour enters the compressor where its pressure
is raised. There will also be a big increase in temperature, because a
proportion of the energy input into the compression process is
transferred to the refrigerant.
3 – 4: The high pressure superheated gas passes from the compressor
into the condenser. The initial part of the cooling process (3 - 3a)
desuperheats the gas before it is then turned back into liquid (3a - 3b).
The cooling for this process is usually achieved by using air or water. A
further reduction in temperature happens in the pipe work and liquid
receiver (3b - 4), so that the refrigerant liquid is sub-cooled as it enters
the expansion device.
4 – 1: The high-pressure sub-cooled liquid passes through the expansion
device, which both reduces its pressure and controls the flow into the
evaporator.
Vapour Absorption Refrigeration
The absorption chiller is a machine, which produces chilled water by
using heat such as steam, hot water, gas, oil etc. Chilled water is produced
by the principle that liquid (refrigerant), which evaporates at low
temperature, absorbs heat from surrounding when it evaporates. Pure
water is used as refrigerant and lithium bromide solution is used as

23
absorbent Heat for the vapour absorption refrigeration system can be
provided by waste heat extracted from process, diesel generator sets etc.
Absorption systems require electricity to run pumps only. Depending on
the temperature required and the power cost, it may even be economical
to generate heat / steam to operate the absorption system.
[15]
In order to keep evaporating, the refrigerant vapour must be discharged
from the evaporator and refrigerant (water) must be supplied. The
refrigerant vapour is absorbed into lithium bromide solution which is
convenient to absorb the refrigerant vapour in the absorber. The heat
generated in the absorption process is led out of system by cooling water
continually. The absorption also maintains the vacuum inside the
evaporator.

24
Chilling Plant Components
A chilling plant has the following components-
 Refrigerants :
A variety of refrigerants are used in vapour compression systems. The
choice of fluid is determined largely by the cooling temperature
required. Commonly used refrigerants are in the family of chlorinated
fluorocarbons (CFCs, also called Freon): R-11, R-12, R-21, R-22 and
R-502.
[16]
 Compressor:
For industrial use, open type systems (compressor and motor as separate
units) are normally used, though hermetic systems (motor and
compressor in a sealed unit) also find service in some low capacity
applications. Hermetic systems are used in refrigerators, air
conditioners, and other low capacity applications. Industrial applications
largely employ reciprocating, centrifugal and, more recently, screw
compressors, and scroll compressors. Water-cooled systems are more
efficient than air-cooled alternatives because the temperatures produced
by refrigerant condensation are lower with water than with air.
Centrifugal Compressors
Centrifugal compressors are the most efficient type when they are operating near
full load. Their efficiency advantage is greatest in large sizes, and they offer

25
considerable economy of scale, so they dominate the market for large chillers.
They are able to use a wide range of refrigerants efficiently, so they will probably
continue to be the dominant type in large sizes.
[17]
A Centrifugal Compressor
Reciprocating Compressors
[18]
The maximum efficiency of reciprocating compressors is lower than that of
centrifugal and screw compressors. Efficiency is reduced by clearance volume (the
compressed gas volume that is left at the top of the piston stroke), throttling losses
at the intake and discharge valves, abrupt changes in gas flow, and friction. Lower
efficiency also results from the smaller sizes of reciprocating units, because motor
losses and friction account for a larger fraction of energy input in smaller systems.
Screw Compressors
Screw compressors, sometimes called “helical rotary” compressors, compress
refrigerant by trapping it in the “threads” of a rotating screw-shaped rotor. Screw
compressors have increasingly taken over from reciprocating compressors of
medium sizes and large sizes, and they have even entered the size domain of
centrifugal machines. Screw compressors are applicable to refrigerants that have
higher condensing pressures, such as HCFC-22and ammonia. They are especially

26
compact. A variety of methods are used to
control the output of screw compressors.
There are major efficiency differences
among the different methods. The most
common is a slide valve that forms a
portion of the housing that surrounds the
screws
[19]
Scroll Compressors
The scroll compressor is an old invention that has finally come to the market. The
gas is compressed between two scroll-shaped vanes.
One of the vanes is fixed, and the other moves within
it. The moving vane does not rotate, but its centre
revolves with respect to the centre of the fixed vane.
This motion squeezes the refrigerant gas along a
spiral path, from the outside of the vanes toward the
centre, where the discharge port is located. The
compressor has only two moving parts, the moving
vane and a shaft with an off-centre crank to drive the
moving vane. Scroll compressors have only recently
become practical, because close machining
tolerances are needed to prevent leakage between
the vanes, and between the vanes and the casing.
[20]
 Evaporators:
Two types of evaporators are used in water chillers—the flooded shell and tube and
the direct expansion evaporators (DX). Both types are shell and tube heat
exchangers. Flooded shell and tube heat exchangers are typically used with large
screw and centrifugal chillers, while DX evaporators are usually used with positive
displacement chillers like the rotary and reciprocating machines. While water is
the most common fluid cooled in the evaporator, other fluids are also used. These
include a variety of antifreeze solutions, the most common of which are mixtures
of ethylene glycol or propylene glycol and water. The use of antifreeze solutions
significantly affects the performance of the evaporator but may be needed for low
temperature applications. The fluid creates different heat transfer characteristics
within the tubes and has different pressure drop characteristics. Machine
performance is generally derated when using fluids other than water.

27
Flooded Shell and Tube
The flooded shell and tube heat exchanger has the cooled fluid (usually water)
inside the tubes and the refrigerant on the shell side (outside the tubes). The liquid
refrigerant is uniformly distributed along the bottom of the heat exchanger over the
full length. The tubes are partially submerged in the liquid. Eliminators are used as
a means to assure uniform distribution of vapour along the entire tube length and
to prevent the violently boiling liquid refrigerant from entering the suction line. The
eliminators are made from parallel plates bent into Z shape, wire mesh screens, or
both plates and screens. An expansion valve maintains the level of the refrigerant.
The tubes for the heat exchanger are usually both internally and externally
enhanced (ribbed) to improve heat transfer effectiveness. [21]
Direct Expansion
The direct expansion (DX) evaporator has the refrigerant inside the tubes and the
cooled fluid (usually water) on the shell side (outside the tubes). Larger DX
evaporators have two separate refrigeration circuits that help return oil to the
positive displacement compressors during part-load. DX coolers have internally
enhanced (ribbed) tubes to improve heat transfer effectiveness. The tubes are
supported on a series of polypropylene internal baffles, which are used to direct
the water flow in an up-and-down motion from one end of the tubes to the other.
Water velocities do not exceed approximately 1½ to 2½ feet per second due to
pressure drop considerations.
[22]

28
 Condensers:
There are a number of different kinds of condensers manufactured for the
packaged water chiller. These include water-cooled, air-cooled, and
evaporative-cooled condensers. A horizontal shell and tube condenser has
straight tubes through which water is circulated while the refrigerant surrounds
the tubes on the outside. Hot gas from the compressor enters the condenser at
the top where it strikes a baffle. The baffle distributes the hot gas along the entire
length of the condenser. The refrigerant condenses on the surface of the tubes
and falls to the bottom where it is collected and directed back to the evaporator.
[23]
Heat rejection commonly used in chiller plants is the air-cooled refrigerant
condenser. This can be coupled with the compressor and evaporator in a
packaged air-cooled chiller or can be located remotely.. Air-cooled condensers,
whether remote or packaged within an air-cooled chiller, normally operate with
a temperature difference between the refrigerant and the ambient air of 10 to
30°F with fan power consumption of less than 0.08 hp/ton (> 69
COP).Maximum size for remote air-cooled refrigerant condensers is about 500
tons, with 250-ton maximum being more common. Air-cooled chillers are
available up to 400 tons.
 Centrifugal Pump:
In the chilled water plant centrifugal pumps are the prime movers that create
the differential pressure necessary to circulate water through the chilled and
condenser water distribution system. In the centrifugal pump a motor rotates an
impeller that adds energy to the water after it enters the centre (eye). The
centrifugal force coupled with rotational (tip speed) force imparts velocity to the
water molecules. The pump casing is designed to maximize the conversion of
the velocity energy into pressure energy. In the HVAC industry most pumps
are single stage (one impeller) volute-type pumps that have either a single inlet
or a double inlet (double suction). Axial-type pumps have bowls with rotating
vanes that move the water parallel to the pump shaft. These pumps are likely to
have more than one stage (bowls).

29
IFB Chilling plants
IFB, Taratala plant has three chilling plants out of them two were
operational during making this report. The chilling plants are –
 36 TR Blue Star Air Cooled Scroll Chiller ( Old )
 36 TR Blue Star Air Cooler Scroll Chiller (New)
 24 TR Blue Star Air Cooled Scroll Chiller
In this report performance of only the 36 TR chillers will be noted
as the 24 TR chiller was not operational.
Chilling Plant Layout
In the layout, pump 3 and pump 4 are pumping hot water from hot water tank
and delivering it to the chiller. These pumps are called Primary Pumps. When
one pump is operational the other one is stand-by.
Pump 1 and pump 2 are pumping chilled water from the chiller output and
delivering it to the chilled water tank. These pumps are called Secondary Pumps.
When one pump is operational the other one is stand-by.
Pump 5 is provided as a bypass pump to balance the whole chiller plant and on
case of high load this pump distribute hot water to the other chiller.

30
In the layout, pump 3 and pump 4 are pumping hot water from hot water tank
and delivering it to the chiller. These pumps are called Primary Pumps.
When one pump is operational the other one is stand-by.
Pump 1 and pump 2 are pumping chilled water from the chiller output and
delivering it to the chilled water tank. These pumps are called Secondary
Pumps. When one pump is operational the other one is stand-by.
Pump 5 is provided as a bypass pump to balance the whole chiller plant and
on case of high load this pump distribute hot water to the other chiller. The
extra tank is provided to incorporate the chilled water from the 24 TR chiller.
Source of hot water:
Inside the fine blanking presses, for smooth operation of every [24]

31
moving components, hydraulic oil are provided in the machines
and in the hydraulic cylinders, actuators oil is constantly moving
thus generating a massive amount of heat. The fine blanking
presses are provided with oil coolers, i.e. heat exchangers where
the hot oil and chilled water are exchanging heat so that oil gets
cooled and water absorbs the heat. By pipeline connection the hot
water from every blanking presses are coming to hot water tank in
the chilling plant.
A typical oil cooler specification of the 650 Ton FB press is -
Oil cooler – 1pc
Heat Exchange Capacity – 80 kw/h
Flow rate of cooling water 150 or more Litre / min
Specifications of Chilling Plant Components:
Air Cooled Scroll Chiller Package
[25]

32
 Manufactured by Blue Star
 Model No. – XAC 3S – 036
 3 Compressor type- Scroll hermetic
 Compressor manufactured by Danfross
 Thermally protected system
 Refrigerant – R 22
 Lubricant mineral oil – 160 P
 Capacity- 36 TR
 Refrigerant Air Dryer
Centrifugal Pump
In both the chilling plants (old and new) centrifugal pumps are provided
with high head and flow capacity value. Due to decay some specifications
cannot be collected for calculation it is assumed that all the pumps are
specified as:
Manufactured By – Kirloskar Brothers [26][27]
For Old Chiller Model No. – KDS 325 ++ KW/HP- 2.2 / 3 Efficiency – 60 % Head Range- 10 – 26 m
Capacity Range – 9.2 – 4. 9 litre / sec and For New Chiller Model No. - KDS 1040+ kW/HP=7.5/10

33
Observation Data Sheet
EWT – Entry Water Temperature LWT – Leaving Water Temperature (units are in degree
centigrade)
C1: Current in compressor 1 C2: Current in compressor 2 C3: Current in compressor 3 (units in A)
Date: 24/12/2014 Old Chiller (Left)
Time EWT LWT C1 C2 C3
10:00 12.2 10.1 21 0 * 0
10:30 13.4 11.2 0 22 0
11:00 15.3 11.0 22 22 0
11:30 14.9 12.6 22 22 0
12:00 17.2 12.4 22 21 22
12:30 18.4 11.9 22 21 23
01:00 16.2 12.2 21 21 0
02:00 13.2 12.5 21 0 0
02:30 15.3 12.0 21 22 0
03:00 18.2 12.1 22 22 22
03:30 19.6 12.9 22 22 22
04:00 18.2 13.2 22 22 22
04:30 14.2 11.2 22 22 0
Date: 24/12/2014 New Chiller (Right)
10:00 14.1 10.1 21 26 0
10:30 15.2 11.6 21 25 0
11:00 16.9 12.9 22 27 21
11:30 17.1 12.6 22 27 23
12:00 16.8 12.4 22 28 22
12:30 14.2 11.9 22 0 23
01:00 14.5 11.1 21 27 0
02:00 19.2 12.4 21 28 22
02:30 17.3 14.0 21 28 0
03:00 19.3 12.8 23 27 22
03:30 18.4 12.6 22 26 22
04:00 16.9 10.2 22 27 22
04:30 18.2 13.5 22 28 21
10:30 11.6 10.0 21 0 0
11:00 13.3 10.9 22 0 0
11:30 15.6 9.3 22 22 23
12:00 14.2 8.2 22 23 22
12:30 15.1 10.9 22 22 23
01:00 14.7 11.2 22 22 22
02:00 12.4 11.3 21 0 0
02:30 16.3 12.0 21 23 0
03:00 15.3 12.8 23 22 22
*Compressor current = 0 means the corresponding compressor is off

34
10:30 17.4 12.0 21 26 22
11:00 16.2 11.9 22 27 23
11:30 18.6 12.3 21 27 23
12:00 19.2 13.2 22 28 22
12:30 18.5 10.9 22 27 23
01:00 14.8 11.2 22 27 22
02:00 11.4 11.3 0 0 0
02:30 15.2 11.4 21 0 22
03:00 15.8 11.8 22 0 23
10:00 18.3 12.1 21 22 22
10:30 17.9 12.5 22 22 22
11:00 18.3 11.9 22 22 23
11:30 16.1 12.8 22 22 0
12:00 18.8 12.4 22 22 23
12:30 17.9 11.8 22 22 23
01:00 15.3 10.1 21 21 23
02:00 14.2 11.4 21 0 23
02:30 15.3 10.0 21 22 22
03:00 16.3 10.4 22 23 22
03:30 17.4 12.7 22 22 22
04:00 15.8 11.2 22 22 22
10:00 12.3 11.9 0 0 0
10:30 13.2 11.5 21 0 0
11:00 14.3 12.1 22 0 23
11:30 14.9 10.8 22 27 0
12:00 13.7 9.4 22 28 21
12:30 15.8 11.7 22 26 22
01:00 16.3 11.4 21 26 21
02:00 16.8 10.8 21 27 22
02:30 15.3 12.0 21 0 22
03:00 16.3 11.5 22 28 22
03:30 19.2 12.1 21 27 22
04:00 18.2 12.2 22 28 22
10:30 16.6 10.7 21 22 22
11:00 15.5 11.4 0 21 23
11:30 16.3 12.2 21 22 23
12:00 17.2 12.9 22 22 22
12:30 17.8 13.5 22 0 23
01:00 18.1 12.0 22 22 22
02:00 17.4 11.3 21 22 20
02:30 16.5 11.2 21 24 21
03:00 17.6 11.6 20 24 20

35
10:30 25.3 16.7 20 26 22
11:00 26.1 17.3 22 27 21
11:30 23.2 16.2 22 28 22
12:00 19.6 13.1 22 28 22
12:30 18.5 11.1 21 26 23
01:00 19.5 12.2 22 27 22
02:00 15.4 11.3 22 0 22
02:30 19.4 12.8 21 25 22
03:00 20.9 13.2 22 26 22
10:15 14.8 9.4 22 23 23
10:30 12.2 10.1 23 0 0
11:00 12.3 8.7 0 24 0
11:30 12.5 10.8 25 0 0
12:00 11.2 11.1 0 0 0
12:30 11.9 10.5 0 0 25
01:00 13.2 9.3 24 24 0
02:00 15.5 9.9 24 25 25
02:30 11.9 11.8 0 0 0
10:15 19.9 13.5 23 27 23
10:30 19.1 13.0 23 27 23
11:00 17.8 11.7 24 28 23
11:30 14.5 10.6 25 28 0
12:00 12.6 10.8 0 28 0
12:30 13.8 13.7 0 0 0
01:00 15.1 11.2 24 23 0
02:00 17.7 11.7 24 28 24
02:30 15.7 11.6 25 0 24
10:30 21.6 14.8 22 25 24
11:00 23.8 16.6 23 24 24
11:30 21.4 14.7 23 24 24
12:00 11.6 11.8 24 0 0
12:30 11.9 11.0 0 0 0
01:00 12.5 10.3 0 0 24
02:00 11.6 10.0 0 0 24
02:30 17.2 11.3 23 24 24
03:00 18.2 12.2 23 25 24
10:30 20.2 13.9 24 28 24
11:00 20.8 14.7 23 27 23
11:30 20.9 14.9 23 28 23

36
12:00 21.2 14.9 25 28 24
12:30 22.0 15.6 25 28 24
01:00 21.1 14.9 23 29 25
02:00 21.6 15.2 25 28 24
02:30 18.3 12.5 24 28 24
03:00 16.5 10.6 24 28 23
10:30 11.7 11.6 0 0 0
11:00 12.4 11.0 22 0 0
11:30 11.5 10.0 23 0 0
12:00 11.7 11.6 0 0 0
12:30 12.9 10.4 0 0 24
01:00 12.5 10.3 0 0 24
02:00 13.7 10.1 0 22 0
02:30 14.2 9.3 23 24 21
03:00 15.2 10.2 23 22 21
10:30 23.2 13.9 24 25 25
11:00 25.8 14.7 0 (Tripped) 26 25
11:30 21.2 14.9 0(Tripped) 28 25
12:00 26.4 14.9 0(Tripped) 28 25
12:30 24.1 15.6 0(Tripped) 27 24
01:00 26.8 14.9 0(Tripped) 25 25
02:00 22.3 15.2 0(Tripped) 26 25
02:30 23.6 12.5 23 24 25
03:00 20.3 10.6 21 25 23
10:30 12.5 8.3 21 21 0
11:00 13.8 10.6 21 21 21
11:30 15.4 10.0 21 22 22
12:00 14.6 11.9 22 22 0
12:30 14.9 11.4 21 23 0
01:00 11.2 10.2 0 0 22
02:00 12.6 11.1 0 0 22
02:30 12.9 11.8 21 0 21
03:00 16.5 12.3 23 0 22
10:30 15.5 13.1 22 0 0
11:00 15.1 10.5 21 25 0
11:30 15.3 11.2 22 24 0
12:00 14.2 9.6 22 26 0
12:30 15.4 10.9 21 25 0
01:00 14.1 11.1 0 25 0
02:00 16.2 12.1 22 26 0
02:30 14.9 11.5 23 26 0
03:00 15.4 12.6 21 26 23

37
10:30 25.5 17.5 23 23 24
11:00 18.9 12.1 23 23 24
11:30 18.3 11.4 22 22 22
12:00 15.7 9.5 22 22 22
12:30 14.5 8.5 21 23 22
01:00 12.6 10.8 0 0 22
02:00 12.9 11.5 0 0 22
02:30 14.6 11.4 21 0 23
03:00 18.6 12.4 23 22 21
10:30 18.4 11.2 22 26 22
11:00 16.4 10.3 22 26 22
11:30 15.3 11.6 0 26 22
12:00 18.1 11.0 22 26 22
12:30 17.6 13.5 0 26 22
01:00 19.0 12.0 21 25 22
02:00 18.8 12.6 22 26 22
02:30 17.5 11.9 23 26 22
03:00 18.6 12.1 21 26 23
10:30 15.4 9.9 23 23 22
11:00 15.7 12.2 23 23 0
11:30 18.9 11.8 22 23 24
12:00 17.5 10.9 22 22 22
12:30 18.2 13.1 21 22 22
01:00 15.6 10.7 0 22 22
02:00 13.5 12.5 0 0 22
02:30 14.6 10.3 21 0 23
03:00 16.7 11.4 23 24 22
10:30 23.4 16.2 22 26 22
11:00 22.4 15.6 22 27 22
11:30 20.5 14.0 23 26 22
12:00 21.1 14.5 22 26 22
12:30 19.5 13.1 22 26 22
01:00 19.0 12.3 23 27 22
02:00 19.6 13.4 21 28 22
02:30 16.5 12.2 0 26 22
03:00 17.8 11.1 21 26 23

38
Date: 15/1/2015 Old Chiller (Left) Test Duration – 60 min Steady State Condition Test (BEE Approved)
Time EWT LWT C1 C2 C3 KWh
12:45 11.6 10.0 21 0 * 0 836
12:50 11.6 9.9 0 22 21 841
12:55 13.3 10.9 22 21 0 846
1:00 15.4 9.3 23 22 22 851
01:05 14.2 8.2 22 22 22 856
01:10 14.2 7.9 22 20 23 862
01:15 15.6 9.3 21 21 24 868
01:20 14.0 8.0 21 22 22 874
01:25 14.1 8.0 21 22 22 880
01:30 15.0 8.7 22 21 22 886
01:35 13.6 7.8 22 20 22 893
01:40 13.5 9.1 22 22 22 899
01:45 14.7 8.3 22 22 22 905
Date: 13/1/2015 New Chiller (Right) Test Duration – 60 min Steady State Condition Test (BEE Approved)
Time EWT LWT C1 C2 C3 KWh
12:46 16.6 11.4 22 25 22 207
12:51 15.5 12.2 0 24 21 218
12:56 17.2 12.9 22 0 21 221
1:01 17.8 13.5 23 24 21 228
01:06 18.1 12.0 22 24 21 235
01:11 17.4 11.3 22 26 23 241
01:16 16.3 11.3 21 27 24 249
01:21 16.5 10.4 21 28 22 257
01:26 16.9 10.5 21 0 22 265
01:31 17.3 10.9 22 26 22 272
01:36 17.2 11.2 22 25 22 279
01:41 17.7 11.6 22 27 22 287
01:46 18.1 12.3 22 28 22 295
According to Bureau of Energy Efficiency standard, after establishing
that steady-state conditions, three sets of data shall be taken, at a
minimum of five-minute intervals. To minimize the effects of transient
conditions, test readings should be taken as nearly simultaneously.

39
Performance Terminologies & Measurement
Tons of refrigeration (TR): One ton of refrigeration is the amount of cooling obtained by one
ton of ice melting in one day: 3024 kCal/h, 12,000 Btu/h or 3.516 thermal kW.
Net Refrigerating Capacity: A quantity defined as the mass flow rate of the evaporator water
multiplied by the difference in enthalpy of water entering and leaving the cooler, expressed in
kCal/h, tons of Refrigeration.
KW/ton rating: Commonly referred to as efficiency, but actually power input to compressor
motor divided by tons of cooling produced, or kilowatts per ton (kW/ton). Lower kW/ton
indicates higher efficiency.
Coefficient of Performance (COP): Chiller efficiency measured in Btu output (cooling) divided
by Btu input (electric power).
Energy Efficiency Ratio (EER): Performance of smaller chillers and rooftop units is frequently
measured in EER rather than kW/ton. EER is calculated by dividing a chiller's cooling capacity
(in Btu/h) by its power input (in watts) at full-load conditions. The higher the EER, the more
efficient the unit.
Performance calculations:
The energy efficiency of a chiller is commonly expressed in one of the three
following ratios: [28]
[29]
IPLV (Integrated Part Load Value):
Chillers rarely operate at their full rated cooling capacity. In fact, most chillers operate at full
load for less than one percent of their total operating hours. Thus, it follows that selecting a

40
chiller based solely on its full load efficiency might not lead to the most efficient selection on a
year-round basis.
Integrated Part Load Value (IPLV) is a metric that is often used to express average chiller
efficiency over the range of loads encountered by most chillers. IPLV is the weighted average
cooling efficiency at part load capacities related to a typical season rather than a single rated
condition, based upon a representative load profile that assumes the chiller operates as follows:
Where: A = kW/ton at 100% capacity B = kW/ton at 75% capacity C = kW/ton at 50%
capacity D = kW/ton at 25% capacity
100% load: 1% of operating hours 75% load: 42% of operating hours50% load: 45% of
operating hours 25% load: 12% of operating hours. When the chiller energy efficiency is
expressed in kW/ton,
[30]
Measurement:
1. Flow rate of chilled water:
In the absence of an on-line flow meter the chilled water flow can be measured by the following
methods
• In case where hot well and cold well are available, the flow can be measured from the tank
level dip or rise by switching off the secondary pump.
• Non-invasive method would require a well calibrated ultrasonic flow meter using which the
flow can be measured without disturbing the system
• If the waterside pressure drops are close to the design values, it can be assumed that the
water flow of pump is same as the design rated flow.
2. Hot water and chilled water temperatures: Directly from chiller control-panel.
3. Compressor Power: The compressor power can be measured by a portable power analyser
which would give reading directly in kW.If not, the ampere has to be measured by the available
on-line ammeter or by using a tong tester. The power can then be calculated by assuming a
power factor of 0.9 Power (kW) = √3 x V x I x cosφ V= Line Voltage; I= Current in
compressor; cosφ= power factor
Calculation of capacity of chiller: [31]

41
Sample Calculation
Old Chiller (Left):
Calculation of Refrigeration capacity
The required parameters are 1. Mass flow rate of chilled water 2. Specific
heat 3. Chilled water temperature at evaporator inlet 4. Chilled water temperature
at evaporator outlet
Assumption: 1.Mass flow rate of chilled water is not measured by any flowmeter
but calculated from chilled water pump capacity range data. 2. The inlet and
outlet temperature value is noted from the chiller control panel in steady-
state condition.
Pump capacity range – 9.2 – 4.9 litre/sec (10 m – 26 m head)
Taken value = 4.9 litre / sec = 17640 kg/hr Cp = 1 kCal/kg o
C for water
Taken steady state value= T inlet = 15.2 o
C T outlet = 9.6 o
C
Net Refrigeration Capacity = ((17640)*1*(15.2 - 9.6)) /3024 = 32.66 TR
Calculation of Compressor Power:
Compressor power is calculated from three phase line voltage neglecting other power
consumptions. Compressor current is noted from the chiller control panel.
Line Voltage – 415 V Power factor(cosφ)= 0.9 A sample data is taken from steady
state condition. C1=22 A C2 = 22 A C3 = 22 A
Compressor power = (W) = √3 x V x I x cosφ=√3 x 415 x (22+22+22) x 0.9
=42.696 kW
kW/Ton Rating for chiller = (42.696/32.66) = 1.334
Coefficient of Performance (COP) = 3.516/1.334= 2.63
Energy Efficient Ratio (EER) = 12 / 1.334 = 8.99
Chilled water pump energy consumption:
kW=(17.6 x 26x1)/(270x1.36x.6)= 2.07
kW/Ton rating for pump= 2.07/32.66=.063 kW/TR
Overall kW/TR= 1.334+.063=1.397

42
New Chiller (Right):
Calculation of Refrigeration capacity
Taken value = 5.6 litre / sec = 20160 kg/hr Cp = 1 kCal/kg o
C for water
Taken steady state value= T inlet = 16.2 o
C T outlet = 11.8 o
C
Net Refrigeration Capacity = ((20160)*1*(16.2 – 11.8)) /3024 = 29.3 TR
Calculation of Compressor Power:
Compressor power is calculated from three phase line voltage neglecting other
power consumptions. Compressor current is noted from the chiller control panel.
Line Voltage – 415 V Power factor (cosφ) = 0.9
A sample data is taken from steady state condition. C1=21 A C2 = 26 A C3 = 23 A
Compressor power = (W) = √3 x V x I x cosφ=√3 x 415 x (21+26+23) x 0.9
=45.284 kW
kW/Ton Rating = (42.696/32.66) = 1.545
Coefficient of Performance (COP) = 3.516/1.545= 2.275
Energy Efficient Ratio (EER) = 12 / 1.545 = 7.76
Chilled water pump power consumption
kW=(20.2 x 40x1)/(270x1.36x.6)= 3.66
kW/Ton rating for pump= 3.66/29.3=.125 kW/TR
Overall kW/TR= 1.545+.125=1.670
*Due to unavailability of some measuring instruments like anemometer, flow
meter , dry bulb temperature meter , condenser fan wattage cannot be calculated.

43
Performance Analysis
The theoretical Coefficient of Performance (Carnot), COP Carnot - a standard
measure of refrigeration efficiency of an ideal refrigeration system- depends on
two key system temperatures, namely, evaporator temperature Te and condenser
temperature Tc with COP being given as:
COPCarnot = Te / (Tc - Te)
This expression also indicates that higher COPCarnot is achieved with higher
evaporator temperature and lower condenser temperature. [32]
Based on calculation in the previous section, COP is determined with hourly data
of the new and old chiller in the IFB plant.
Old Chiller (left)
Date Time COP % Load EER kW/TR
24/12/2014 10:00 2.85 34 9.75 1.23
12:00 2.14 77 7.31 1.64
2:00 1.037 11 3.53 3.39
4:00 2.39 81 8.15 1.47
Average 2.10 50.75 7.185 1.93
26/12/2014 10:00 2.42 25 8.2 1.45
12:00 2.85 97 9.75 1.23
2:00 1.66 17 5.686 2.11
4:00 1.168 40 3.38 3.01
Average 2.02 44.75 6.754 1.95
27/12/2014 10:00 2.97 98 10.13 1.18
1:00 2.54 84 8.68 1.38
4:00 2.21 74 7.53 1.59

44
Average 2.57 85.3 8.78 1.38
30/12/2014 10:00 2.88 95 9.81 1.22
1:00 2.81 98 9.97 1.25
4:00 2.52 82 8.62 1.39
Average 2.73 91.6 9.46 1.28
2/01/2015 10:00 2.56 88 8.73 1.37
1:00 2.58 63 8.78 1.36
4:00 2.40 90 8.18 1.46
Average 2.51 80.33 8.56 1.39
3/01/2015 10:00 2.45 61 8.39 1.43
1:00 2.62 45 8.95 1.34
4:00 2.39 95 8.16 1.47
Average 2.48 67 8.5 1.39
New Chiller (Right)
Date Time COP % Load EER kW/TR
24/12/2014 10:00 3.16 76 10.81 1.11
1:00 2.56 63 8.75 1.37
4:00 2.56 92 8.75 1.37
Average 2.76 77 9.43 1.28
26/12/2014 10:00 2.81 100 9.6 1.25
12:00 1.84 66 6.28 1.91
4:00 3.22 74 11.00 1.09
Average 2.62 80 8.96 1.95
27/12/2014 10:00 2.95 31 10.08 1.19
1:00 2.62 90 8.95 1.34
4:00 2.511 53 8.57 1.40
Average 2.69 58 9.2 1.38
30/12/2014 10:00 3.33 75 11.385 1.054
1:00 2.72 100 9.30 1.29
4:00 1.81 70 6.18 1.94
Average 2.62 81 8.95 1.28
2/01/2015 10:00 1.74 75 6.97 1.72
1:00 3.03 72 10.34 1.16
4:00 3.03 76 10.34 1.16
Average 2.60 74.33 9.21 1.34
3/01/2015 10:00 2.09 81 7.14 1.68
1:00 2.31 91 7.89 1.52
4:00 2.28 87 7.79 1.54
Average 2.22 86.33 7.60 1.58

45
IPLV Calculation for Old Chiller(Left):
From the above chart
A = kW/TR at 100 % load=1.25
B= kW/TR at 75 % load =1.59
C= kW/TR at 50 % load = 1.93
D= kW/TR at 25 % load = 1.45
IPLV=1/ ((0.01/1.25) + (.42 / 1.59 ) + (.45/1.93) + (.12/1.45)) = 1.70
IPLV Calculation for New Chiller (Right):
From the above chart
A = kW/TR at 100 % load=1.25
B= kW/TR at 75 % load =1.34
C= kW/TR at 50 % load = 1.38
D= kW/TR at 25 % load = 1.19
IPLV=1/ ((0.01/1.25) + (.42 / 1.34 ) + (.45/1.38) + (.12/1.19)) = 1.33
The term IPLV is used to signify the cooling efficiency related to a typical
(hypothetical) season rather than a single rated condition. The IPLV is calculated
by determining the weighted average efficiency at part-load capacities specified by
an accepted standard. It is also important to note that IPLVs are typically
calculated using the same condensing temperature for each part-load condition
and IPLVs do not include cycling or load/unload losses. The units of IPLV are
not consistent in the literature; therefore, it is important to confirm which units
are implied when the term IPLV is used. ASHRAE Standard 90.1 (using ARI
reference standards) uses the term IPLV to report seasonal cooling efficiencies
for both seasonal COPs (unit less) and seasonal EERs (Btu/Wh), depending on
the equipment capacity category; and most chillers manufacturers report seasonal
efficiencies for large chillers as IPLV using units of kW/ton. Depending on how a
cooling system loads and unloads (or cycles), the IPLV can be between 5 and
50% higher than the EER at the standard rated condition
*here IPLV is calculated on short term basis.

46
Energy Saving Opportunity
Maintenance
Maintenance of Heat Exchanger Surfaces:
Heat transfer can also be improved by ensuring proper separation of the lubricating
oil and the refrigerant, timely defrosting of coils, and increasing the velocity of the
secondary coolant (air, water, etc.). However, increased velocity results in larger
pressure drops in the distribution system and higher power consumption in pumps
/ fans. Therefore, careful analysis is required to determine the most effective and
efficient option. Fouled condenser tubes force the compressor to work harder to
attain the desired capacity.
For example, a 0.8 mm scale build-up on condenser tubes can increase energy
consumption by as much as 35 %. Similarly, fouled evaporators (due to residual
lubricating oil or infiltration of air) result in increased power consumption. Equally
important is proper selection, sizing, and maintenance of cooling towers. A
reduction of 0.55°C temperature in water returning from the cooling tower reduces
compressor power consumption by 3.0 %.
Multi-Staging for Efficiency
Efficient compressor operation requires that the compression ratio be kept low, to
reduce discharge pressure and temperature. For low temperature applications
involving high compression ratios, and for wide temperature requirements, it is
preferable (due to equipment design limitations) and often economical to employ
multi-stage reciprocating machines or centrifugal / screw compressors. Multi-
staging systems are of two-types: compound and cascade – and are applicable to all
types of compressors. With reciprocating or rotary compressors, two-stage
compressors are preferable for load temperatures from –20 to –58°C, and with
centrifugal machines for temperatures around –43°C.In multi-stage operation, a
first-stage compressor, sized to meet the cooling load, feeds into the suction of a
second-stage compressor after inter-cooling of the gas. A part of the high-pressure
liquid from the condenser is flashed and used for liquid sub-cooling. The second
compressor, therefore, has to meet the load of the evaporator and the flash gas. A
single refrigerant is used in the system, and the work of compression is shared
equally by the two compressors. Therefore, two compressors with low compression
ratios can in combination provide a high compression ratio.
Matching Capacity to System Load
During part-load operation, the evaporator temperature rises and the condenser
temperature falls, effectively increasing the COP. But at the same time, deviation
from the design operation point and the fact that mechanical losses form a greater
proportion of the total power negate the effect of improved COP, resulting in lower

47
part-load efficiency. Therefore, consideration of part-load operation is important,
because most refrigeration applications have varying loads. The load may vary due
to variations in temperature and process
Chilled Water Storage
Depending on the nature of the load, it is economical to provide a chilled water
storage facility with very good cold insulation. Also, the storage facility can be fully
filled to meet the process requirements so that chillers need not be operated
continuously. This system is usually economical if small variations in temperature
are acceptable. This system has the added advantage of allowing the chillers to be
operated at periods of low electricity demand to reduce peak demand charges -
Low tariffs offered by some electric utilities for operation at night time can also be
taken advantage of by using a storage facility. An added benefit is that lower ambient
temperature at night lowers condenser temperature and thereby increases the
COP.
Some ways to minimize energy consumption are -
a) Cold Insulation
Insulate all cold lines / vessels using economic insulation thickness to minimize
heat gains; and choose appropriate (correct) insulation.
b) Building Envelope
Optimise air conditioning volumes by measures such as use of false ceiling and
segregation of critical areas for air conditioning by air curtains.
c) Building Heat Loads Minimisation
Minimise the air conditioning loads by measures such as roof cooling, roof
painting, efficient lighting, pre-cooling of fresh air by air- to-air heat exchangers,
variable volume air system, optimal thermo-static setting of temperature of air
conditioned spaces, sun film applications, etc.
e) Process Heat Loads Minimisation
Minimize process heat loads in terms of TR capacity as well as refrigeration level,
i.e., temperature required, by way of:
i) Flow optimization
ii) Heat transfer area increase to accept higher temperature coolant
iii) Avoiding wastages like heat gains, loss of chilled water, idle flows.
iv) Frequent cleaning / de-scaling of all heat exchangers
[33]

48
Conclusion
I have gained knowledge by this training in various aspects as an
Engineering student, as I had first-hand experience in IFB Industries
Limited. This training enhanced my cognition, as the employee has
explained, with commitment, all the doubts and question that arise in
my mind. This chance thrown at me, was a boon as I had only seen
that real about all the equipment seen in the industry, which now, I am
able to distinguish well enough. This was not possible with theoretical
knowledge. I heartily thanks all employees of IFB, Taratala to have
help me all throughout my training.
Doing this project on HVAC system in IFB, I have gathered clear
knowledge about the chiller performance and also many RAC systems.
I would like to express my gratitude to all those who gave me the
possibility to complete this training. I want to thank the HR department
of IFB for giving me permission to commence this training. It is really
great opportunity for me by which I had learned here many more about
engineering discipline.

49
Reference
The data are taken from following references-
[1] http://www.google.com/images980
[2] Indian Fine Blanks.ppt
[3] http://www.ifbbangalore.com/html/profile.htm
[4] IFB Taratala plant
[5] http://www.google.com/images987
[6] http://www.google.com/images
[10] http://www.ifbbangalore.com
[13] Bureau of Energy Efficiency – HVAC guide book- Chapter 4 page -1
[14] Chilling Water Plant – Guide book (Energy Resources Guide )
[15] Bureau of Energy Efficiency – HVAC guide book- Chapter 4 page -3
[16] Bureau of Energy Efficiency – HVAC guide book- Chapter 4
[24] http://www.moriiron.com/english/cpt_product/fb
[25] blue star air cooled scroll chiller brochure
[26] blue star air cooled scroll chiller brochure
[27] http://www.kirloskarpumps.com/brochure
[28] Bureau of Energy Efficiency – HVAC energy performance guide book- Chapter 8
[31] Chilling Water Plant – Guide book (Energy Resources Guide)
The list of documents required for preparing this report –
1. ASHRAE Handbook
2. Bureau Of Energy Efficiency guide books
3. ARI Standard 550/590
4. HVAC chillers code draft
5. Energy Star Tools
6. HVAC Systems
7. COOLTOOLS™ CHILLED WATER PLANT DESIGN GUIDE

Report_Chiller(by Sayan Roy)

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