Smart Energy Valves

Technology Overview

These valves, integrated with smart systems, regulate energy flow based on real-time data and demand. By automating and adapting energy distribution, they enhance efficiency, reduce waste, and contribute to sustainable and cost-effective energy management in heating, ventilation, and other systems.

Problem Statement

-- Most valves in operation are manually balanced 2 way valves.
Differential Pressure in the hydronics system that occurs from time to time due to variable loads.
-- Delta T problem as water flows too fast across the coils resulting in inefficient heat transfer. The flow rate just keeps increasing without any effect on BTUH.
-- As a consequence, due to the high flow rate without any significant increase in tonnage or load , the chiller staging up occurs which overall result in unnecessary pumping and chiller running costs.

Solution

Smart valves that can reduce upto 15% of the HVAC energy cost. IoT enabled Valves with ultrasonic flow sensor , actuator, etc that will optimize flow rate and reduce staging up of chillers thereby significantly reducing pumping energy and chiller energy consumption

a. Optimal Chiller Loading with Delta T Optimization and Pressure Independence from the Hydronics system
b. Reduction of unnecessary pumping costs due to optimal flow rate
c. Preventive Maintenance & Less Downtime : Coils Fouling can be detected early when Delta T is not increasing despite an optimal flow rate.
d. IoT enabled - 55+ critical data points recorded on the cloud to analyze the historical data anytime.

Valve is operated 15 days each in :
a. Position Control mode (i.e your present mode)
b. Flow Control/Pressure Independence + Delta T Limiting mode
c. Power mode - Allows you to set your heat transfer thermal power output to a maximum full load value with a linear heat transfer response throughout the entire load range. The coil and valve characteristics become irrelevant making the valve pressure and temperature independent
d. Your present mode findings will serve as the baseline for savings calculation

EC Plus Fans for AHUs

Technology Overview

Problem Statement

Plug and Centrifugal which only utilize the static pressure cannot achieve efficiencies above 70%, as the dynamic pressure goes to waste. To maximize the energy efficiency of any ventilation system, fans must use both static and dynamic pressures.

Many plug/centrifugal fans reach efficiencies only between 65-70%.

Solution

EC Plus fans provide unmatched efficiencies of up to 85%. These efficiencies push fan designs to new levels, and thus lower the overall power consumption and sound.
The concept prescribes components for optimal system design – permanent magnet motors, VFDs, and highly efficient axial flow
With motor and frequency drive efficiencies both reaching above 95%, the overall system efficiency is brought to 85%.
At least 20 % compared to best-in-class EC fans.
Typically 40% by retrofit of old plug fans.
Typically 50% by retrofit of old centrifugal fans.

Case study – Bosch Bidadi Plant

Existing system

The facility had 16 AHUs with each having 35,000 CFM capacity, total 560,000 CFM to supply fresh air to 1.5 lac Sqft hanger.
The existing system had Centrifugal belt driven blowers with airflow capacity of 35,000 CFM at 75mmWC.
These blowers were fitted with 18.5 kW IE2 motors and airflow was regulated with Variable Frequency Drives (VFD)
M&V done for 2 AHUs for 2 days

Key Features

a. The Multi-stage system consist of indirect/direct evaporative cooling system, chilled water & Hot water coils
b. In Indirect evaporative cooling, Sensible energy of the inlet air is reduced by reducing temperature without changing specific humidity (Like cooling tower)
c. In direct cooling, water evaporates directly into the air stream, thus reducing the air’s dry-bulb temperature while humidifying the air. (Like Air cooler)
d. Hot water coil is used during post monsoon and winter seasons when shop floor temperature falls below 15°C. Energy Efficient Heat pump is used to generate Hot water as per the set conditions

Advantages

a. The integrated cooling system saves around 55-60% over conventional chiller based HVAC system of similar TR load
b. EC plus fans saves around 40-45% over conventional belt driven centrifugal fans

Case study of Collins Aerospace

-- Facility had 04 hangars with the total area of 92000 Sft, divided equally into ground and mezzanine floors
-- The working condition to be maintained with Temp-28°C ±1°C and RH-below 65%
-- net heat load of 587 TR with fresh air supply of 294,000 CFM to establish required working conditions
-- Hybrid heating and cooling chiller of 440 TR (02 Nos x 220 TR) with heating capacity of 1800 kW (02 Nos x 950 kW) & AHU with total capacity of 324000
-- AHU was designed to accommodate fresh air filters, fans, IDEC, DEC, Chilled water coil and ports for primary and secondary air movement. Electronically Commutated (EC) fans were introduced in AHUs in this project to save energy and have easy control on airflow
-- BMS having PLC based control system was provided which works on process logic based on room and ambient air conditions

-- Multi-stage Cooling has helped this facility to reduce heat load of 587 TR by 60% saving
-- The evaporative cooling including DEC and IDEC was used in summer season while IDEC is used in Monsoon season
-- It was assessed that on 64% energy saving achieved over conventional system

Syncro’s SUIIT S platform changes the game with respect to VAV, BMS and HVAC fit-out commissioning.
Globally, it is the only platform available that Integrates all aspects of the HVAC fit-out that Simplifies, Standardizes and enables early Integration testing by virtue of bringing People, Process and Technology together on a unified cloud platform, where everything is connected
For a typical project, it reduces commissioning time-lines by 80%, saving significant costs, reduces risks significantly and helps deliver a fully integrated and scientifically tested system
Advanced Analytics and AI algorithms provide invaluable insights into system performance and predict failures of equipment and systems greatly enhancing maintenance capabilities