Case study plant4 putrajaya[arul hisham]
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This document describes the development of Malaysia's first satellite remote chilled water storage system for district cooling. The system was built at Gas District Cooling's PJP4 plant in Putrajaya to store up to 100,000 tons of chilled water generated from the existing PJP2 plant during off-peak hours. The 45-meter diameter concrete tank, one of the largest in the world, helps meet peak cooling demand while reducing electrical imports and carbon emissions by 43% compared to operating electric chillers alone. Performance monitoring shows the stratified storage system operates as designed with a thin thermocline and high efficiency.
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Case study plant4 putrajaya[arul hisham]
- 1. 3RD ANNUAL ASIA PACIFIC DISTRICT COOLING CONFERENCE KUALA LUMPUR 26 – 28TH AUGUST 2014 DEVELOPMENT OF THE MALAYSIA’S FIRST SATELLITE REMOTE CHARGING 100,000RTH CHILLED WATER STORAGE SYSTEM AT GAS DISTRICT COOLING (GDC) PJP4 AT LOT 4U2, PRECINCT 4, PUTRAJAYA CORE ISLAND BY IR. ARUL HISHAM BIN ABDUL RAHIM BSME, P.Eng, FIEM, MASHRAE, MACEM PRINCIPAL AHAR Consultants LEAD CONSULTANT PJP4
- 2. BACKGROUND OF AHAR Consultants 2
- 4. 4 OUTLINE
- 6. 6 GDC (P) SDN BHD OWNER Putrajaya Holdings DEVELOPER KLCC Projeks PROJECT MANAGER AHAR Consultants LEAD CONSULTANT Prisma Athira Architects ARCHITECT Total Project Solution Consultant C&S ENGINEER AS2 Sdn Bhd QUANTITY SURVEYOR FVB Energy Inc USA TECHNICAL ADVISOR Sunway Construction EPCC BUILDER AHAR Consultants PROCESS AND M&E ENGINEER PROJECT TEAM ORGANIZATION
- 7. DESIGN BRIEF UTILIZATION OF PLOT 4U2 FOR FUTURE COOLING LOAD OF THE CORE ISLAND, PUTRAJAYA WITH SPACE RESERVED FOR FUTURE EXPANSION FULL UTILIZATION OF GAS TURBINE AND EQUIPMENT FROM PJP2; NO START/STOP TURBINE OPERATION MINIMIZE ELECTRICAL POWER IMPORT FROM TNB DURING PEAK PERIOD REASONABLE CAPEX SUSTAINABLE OPEX AND COST OF OWNERSHIP 7
- 8. 8 METHODOLOGY NEED STATEMENT CAPACITY PLANNING (CORE ISLAND) HYDRAULIC STUDY OPTIONS STUDY ON TYPE OF SYSTEM •GENERATION SYSTEMS •PHASING OF EQMT •COST OF OWNERSHIP •UNIT UTILITY COST TANK TYPES OPTIONS •STEEL •CONCRETE: •RECTANGLE •CYLINDRICAL DETAIL DESIGN TENDER & CONSTRUCTION TESTING & COMMISSIONING MONITORING OF PERFORMANCE
- 9. 9 LOCATION PLOT 4U2 PLOT 4U2 PjP4 PULLMAN HOTEL MINISTRY OF FINANCE
- 10. CORE ISLAND CHILLED WATER PIPE 10 RETICULATION NETWORK PjP2 PjP4 FUTURE PLANT
- 11. 11 LOAD PROJECTION & PLANTING UP Projection based on parcels’ development schedule Historical average 3,650RT/yr (2003-09) WE ARE HERE PjP2 Equipment derating Tank 1 Tank 2 4,000RT/yr
- 12. SNAPSHOT OF LOAD PROFILE CORE ISLAND– MARCH 2009 12
- 13. PjP2 GENERATING CAPACITY Equipment Quantity Generating capacity (RT) Firm Generating Capacity (RT) STEAM ABSORPTION CHILLER 11 10 x 2 500 25 000 ELECTRICAL CHILLER 2 2 x 1 250 2 500 DIRECT FIRED CHILLER 2 2 x 1 350 2 700 Σ = 30 200 RT GAS TURBINE 2 2 X 4.5 MW 9.0 MW 13
- 14. 14 THE SOLUTION
- 15. CONCLUSION OF STUDY PJP2 WAS DESIGNED TO GENERATE A MAXIMUM CAPACITY OF 30,200RT. SINCE THERE IS VERY LITTLE NIGHT LOAD, IT IS THEORETICALLY POSSIBLE TO STORE UP TO 300,000RTH OF CHILLED WATER FROM PJP2. PJP4 IS DESIGNED AS A HYBRID PLANT CONSISTING OF CHILLED WATER STORAGE AND CONVENTIONAL CHILLERS. A SATELLITE STRATIFIED CHILLED WATER STORAGE SYSTEM IS SELECTED TO BE INSTALLED AT PJP4 SITE TO STORE THE CHILLED WATER GENERATED FROM PJP2 DURING OFF-PEAK PERIOD. OPERATE PJP2 AT NIGHT TO STORE CHILLED WATER AT PJP4 PJP2 AND PJP4 OPERATE SIMULTINEOUSLY DURING DAYTIME TO MEET COOLING LOAD 15
- 16. PLANT # 4 CHARGE SCENARIO EXISTING PLANT # 2 CHILLER CHILLER CHILLER CHILLER CHILLER CHILLER CHILLER CHILLER OPEN OPEN 16 TES TANK TES TANK 56⁰F / 13.3 C(RETURN) 43⁰F / 6.1C (SUPPLY) 40⁰F / 4.4C (SUPPLY) PIPES WITH NO FLOW
- 17. PLANT # 4 DISCHARGE SCENARIO EXISTING PLANT # 2 CHILLER CHILLER CHILLER CHILLER CHILLER CHILLER CHILLER CHILLER OPEN CLOSED TES TANK TES TANK 56⁰F / 13.3 C(RETURN) 43⁰F / 6.1C (SUPPLY) 40⁰F / 4.4C (SUPPLY) PIPES WITH NO FLOW 17
- 18. 18 PjP4 SITE LAYOUT
- 19. 19 PLAN EQUIPMENT LAYOUT (ULTIMATE)
- 20. PLANT ISOMETRIC PIPING (PHASE 1 WITH 1 UNIT STORAGE TANKS) 20
- 21. PLANT ISOMETRIC PIPING (ULTIMATE PHASE CHW STORAGE TANKS AND ELECTRIC CHILLERS) 21 PJP 4 TES CAP (RTh) ECC (RT) PEAK OUTPUT (RT) PHASE 1 100,000 15,000 PHASE 2 100,000 15,000 PHASE 3 12,000 12,000 TOTAL 42,000 PJP 2 30,200
- 22. 22 ARTIST’S IMPRESSION OF ULTIMATE PjP4
- 23. 23 CONSTRUCTION
- 24. 24 PLANT CONSTRUCTION Tank under construction Stumps for bottom diffuser support Installation of top diffuser Installation of bottom diffuser
- 25. 25 PLANT CONSTRUCTION Tank plinth construction 1200mm pipe installation 750mm tank wall
- 28. 28 BASIC CHW TANK OPERATION CHARGING MODE WARM WATER PIPE OUT PIPE IN THERMOCLINE COLD WATER DIFFUSER PIPE SYSTEM
- 29. BASIC CHW TANK OPERATION 29 DISCHARGING MODE WARM WATER PIPE IN PIPE OUT THERMOCLINE COLD WATER DIFFUSER PIPE SYSTEM
- 30. 30 CHW TANK SPECIFICATIONS AND PERFORMANCE Specifications Design Actual Rated Storage Capacity 100,000 RTh @ 6.5 C dT 109,012 RTh @ 6.5C dT Thermocline Thickness Less than 1.5m Between 0.6 – 1.0m Water Volume 14 Mil US Gallons/53,000 cu.m 11.62 Mil US Gallons/52,862 cu.m Figure of Merit More than 90% 92.5% Rated discharge capacity 12,000 RT 15,991 RT Diffuser Reynolds # Max 2,000 1,991 Diffuser Froude # Less than 0.5 0.09 Heat loss over 24 hours 2% of rated capacity 0.57% of rated capacity
- 31. 31 DIFFUSER THERMOCLINE PERFORMANCE MOST SIGNIFICANTLY IS THE THERMOCLINE THICKNESS AVERAGING 0.8 METERS THICK COMPARED TO 1.5 – 2 METERS THICKNESS COMMONLY ELSEWHERE WORLDWIDE. THIS THIN THERMOCLINE THICKNESS INDICATES THAT THE DIFFUSERS ARE WORKING PROPERLY WHERE THE COLD AND WARM WATER BODIES ARE PROPERLY STRATIFIED IN THE TANK.
- 32. CURRENT 32 OPERATING REGIME MONDAY FRIDAY
- 33. PjP 2 33 EQUIPMENT OPERATION
- 34. 34 BENEFITS 40% OF PEAK LOAD BY TES 4 MW LESS CHILLERS OPERATING DURING PEAK PERIOD
- 35. PjP4 CARBON FOOTPRINT COMPARISON vs GRID CONNECTED CONVENTIONAL CHILLER PLANT 35 1,115 tCO2 PER WK 599 tCO2 NATURAL GAS 28,458 GJ PER WK EMISSION REDUCTION 23,000 tCO2 P.A. GRID ELECTRICITY 50 MWh 1,044 tCO2 PER WK GRID ELECTRICITY 1,409 MWh (APPROX) -43% VS 1,568,000 RTh Cooling Output + Pumping 440,500 RTh Cooling Output + Pumping 440,500 RTh Cooling Output + Pumping
- 36. 36 WRAP UP
- 37. CONCLUSIONS DISTRICT COOLING & THERMAL STORAGE: EXCELLENT TOOL FOR DEMAND SIDE MANAGEMENT SUSTAINABLE ENERGY COST REDUCTION OF ELECTRICITY MAXIMUM DEMAND @ PEAK PERIOD INCREASE THE LOAD SUPPLY CAPABILITY AND ENHANCE THE RELIABILITY AND AVAILABILITY OF THE CHILLED WATER. IMPROVES REDUNDANCY OF THE SYSTEM AS LESS EQUIPMENT IS REQUIRED TO BE RUN DURING PEAK PERIOD BETTER UTILIZATION OF ASSETS 37
- 38. UNIQUENESS OF PjP4 PJP4 HAS BEEN IN OPERATION TO SUPPLY CHILLED WATER TO PRECINCTS 3 AND 4 IN PUTRAJAYA CORE ISLAND SINCE JANUARY 2013. OPERATION RESULTS HAVE SHOWN THAT THE OPERATION OF THIS CHW SYSTEM HAS ACHIEVED THE EXPECTATIONS OF THE OWNER AND DESIGN TEAM. IS THE FIRST REMOTE SATELLITE CHILLED WATER STORAGE SYSTEM FOR A DISTRICT COOLING PLANT IN MALAYSIA CHW TANK DIMENSIONS OF 45M DIAMETER AND 32M HIGH (EQUIVALENT TO A 10-STOREY HIGH BUILDING); WITH 750MM THICK PRE-STRESSED CONCRETE WALL IS BELIEVED TO BE THE BIGGEST REINFORCED CONCRETE CHILLED WATER TANK IN MALAYSIA; AS WELL AS IN THE WORLD CARBON EMISSION OF THE PJP4 IS REDUCED BY 43% COMPARED TO GRID CONNECTED CONVENTIONAL ELECTRIC CHILLER PLANT 38
- 39. 39 THANK YOU We ain’t sell nothing but expertise www.aharconsultants.com.my
Editor's Notes
- This is the outline of the presentation
- This is the methodology during the development of Plant 4. Upon identifying the needs, we proceeded with the capacity planning study of the Core Island. We also did a hydraulic study on the pipe reticulation network to check the hydraulically remote location. During the Option Study phase, we look at various generation technologies; Steam absorption chillers, direct fired chillers, electric centrifugal chillers, thermal storage and various combinations of these technologies. We also looked at the phasing of equipment in relation to the load growth & utilities price increase to arrive to the most optimal cost of ownership and generation unit cost. We also looked at various tank configurations; cylindrical and rectangular as well as the materials to be used.
- This is the aerial view of Putrajaya core island. Plot 4U2 is located mid-way of the core island; behind the Ministry of Youth and Sports building.
- This is the chilled water reticulation network at Core Island. The main pipes are 900mm diameter (in blue) running from Plant 2 all the way to the Southern end. PjP2, commissioned in 2003; designed primarily to serve Precinct 2, was extended to provide cooling to Precincts 3 and 4. There is another plot reserved for future plant at the southern end Precinct 4
- This is the load projections in 2009. The red line is the load projection based on original individual parcel’s schedule. The historical load growth from 2003 to 2009 was averaging 3,650RT per year. Taking into consideration PjP2’s equipment derating, the decision by GDC to construct PjP4 is timely; as the current load is about 25,000 - 26,000RT. GDC is now able to supply the load with sufficient capacity as buffer
- This is a typical weekday cooling load profile of the Core Island in 2009. From 6 to 8 am, the maximum pull down load occurs. Between 6 – 7am much cooling is used to cool the water in the reticulation pipe from 18C down to 6C. The buildings start operation of the air side at about 7am. This load can be as high as 20% of the average load. From 10.30am to 5.30pm, the load is relatively constant. There is very little night load as these buildings are all government offices.
- This is PjP2 available rated generating capacity. The electrical and direct fired chillers are mainly used for peaking loads; as they are more costly to operate. Electrical power generated by the GTs are used in-house and not exported.
- This is the schematic of the system envisaged for PjP4. Charging of the tank is done at night. CHW at 6C from PjP2 is pumped into the tanks at PJP4. In the ultimate phase, electric chillers at PjP4 can be used to cool the CHW further to 4.4C. This would increase the CHW storage capacity by another 30%.
- In the discharging mode, both plants 2 and 4 inject CHW into the reticulation network simultaneously. PJP2 would serve loads at the northern part whilst PjP4 would supply to precincts 3 and 4 at the southern part.
- PjP4 was planned as a hybrid plant consisting of chilled water storage and chillers. The construction of the plant shall be phased. For Phase 1, we install 1 unit of chilled water storage tank of nominal rated capacity of 100,000 RTh with associated booster pumps For Future Phases – additional 1 unit chilled water storage tank of nominal rated capacity of 100,000 RTh and/or installation of electric chillers depending on the load growth
- This is the internal layout of PjP4. The dotted line indicates future plant area.
- This is the pumps layout for Phase 1 and 2
- Ultimately, PjP4 is envisioned to generate 42,000 RT from 30,000 RT from chilled water tanks and 12,000 RT from electric chillers.
- This is an artist impression of the ultimate plant
- These are the photo after the filling up of the tank. The contractor had to use a small boat to go around inside the tank. The middle picture is the inside of the plant building. Currently, only booster pumps are installed with pipe headers ready for connection for future phases.
- This is how charging of chilled water tank. Chilled water at 6C is pumped into the tank from the bottom diffuser. Warm water at 12C is extracted out from tank from the top diffuser It is very important that these water bodies do not get mixed up during this process. These chilled and warm water is separated by a layer of thermocline. To ensure proper formation of thermocline, the diffuser must be properly designed to ensure the water flow is laminar and no mixing takes place.
- The water flows are reversed during discharging process. Warm water enters the tank from top diffuser and chilled water exits the tank from bottom diffuser. The layer of thermocline moves up and down during the charging and discharging process.
- This graph shows detailed equipment operation at PjP2. As can be seen, the chillers output is almost constant day and night at around 15,000RT. By flattening out the chillers output profile, the operation of gas turbine can be better managed as the steam consumption is constant night and day
- Peaking morning pull down load is taken up by PjP4 without having to run additional chillers from PjP2. This has reduced the quantity of chillers required to meet the demand; hence, enhancing the reliability and availability of the overall system. PjP4 is currently discharging about 40% of the peak period load demand. Currently, PjP2 is supplying about 15,000RT and PjP4 supplies averaging 10,000RT. PjP4 also reduces the TNB electricity import of PjP2 by 4MW. 4MW can be translated to about RM154,000 per month of maximum demand savings if we use C2 commercial Tariff at RM38.60/kW max demand.
- If we compare the carbon emission of PjP4 current cooling output to a grid-connected conventional electrical chiller plant with the same output, there is a 43% reduction of CO2 emission. This translates to approximately a reduction of 123,000 tons CO2 per annum
- In summary, using district cooling and thermal storage are excellent tool for electricity demand side management. It helps in the reduction of energy cost by reducing the maximum demand charge during peak period. Having this system, increase the load supply capability and enhance the reliability and availability of the system. Thermal storage also improves the redundancy of the system as less equipment is required during peak period. Therefore, the owner can have standby equipment should any of the machine breaks down.