The document provides a summary of findings from an HVAC audit conducted at Sutherland's Padi facility in Chennai. Key findings include: - Actual capacity utilization of chiller plants, AHUs, and other infrastructure is much lower than installed capacity. - Several issues were observed with AHUs including lack of filters, damaged components, and improper installation. - Facility observations revealed unwanted materials, unclean areas, and other maintenance issues. Recommendations focus on optimization of the HVAC system, changes to distribution, implementing suggested repairs and upgrades, and ongoing maintenance.

1. Results from HVAC Audit of Sutherland’s Padi Facility Presentation to Mr. K.P. Nair & Mr. Ramunni Nair Version 2 November 5, 2007

2. About This Presentation Choice Solutions is submitting this final report of findings and insights based on our HVAC audit of Sutherland’s Padi facility in Chennai. We are submitting this report after getting the feedback from Mr. Manohaur on the previous draft version. We make recommendations for optimization of the entire HVAC infrastructure. We also make strong recommendations for changes in the HVAC distribution system for better coefficient of performance. As the next step, we recommend implementing the suggested changes followed by maintenance of the HVAC infrastructures.

3. Audit Scope of Work Capacity vs. Utilization Chiller Plant AHU Chiller Water Pump Motor Cooling Tower Cooling Water Pump Motor Pipeline Facility Observations and Recommendations Temperature Readings and Analysis Conclusions and Next Steps Agenda

5. Chiller Plant and AHU Audit Activities Check for normal working function of the chiller Check for water gauges function Check for thermometer function Check for butterfly valves at chiller, condenser inlet and outlet Check for periodical cleaning of cooling tower with chemical Check painting on supports for cooling tower, fan and motors Check pressure gauge and thermometer of AHU also Check pre filter Check cooling coils Check three way mixing valves Check drain liner Check fresh air damper Check for air balancing Check for cooling damper

6. Chiller (Technical Information) Compressor oil pressure 6 77PSI 215PSI Refrigerant pressure suction discharge 5 31.92 ˚c Condenser inlet temperature 3 39.20 ˚c Condenser outlet temperature 4 Compressor oil level 7 167Amp 8.4 ˚c 10.0 ˚c Plant No - 2 10.0°C Plant No - 1 Compressor motor current 8 Chiller outlet temperature 2 Chiller inlet temperature 1 Particulars #

7. AHU Air Flow Standard 40TR AHU air volume 16000 CFM Standard 25TR AHU air volume 10000 CFM 16.0 ˚C 15.0 ˚C 14.5 ˚C 14.0 ˚C 13.5 ˚C 15.5 ˚C 12.0 ˚C 12.0 ˚C Canvas Temperature 6992 22.0 ˚C 8 th Floor 25TR 6 10778 23.0 ˚C 8 th Floor 40TR 5 12253 22.5 ˚C 7 th Floor 40TR 3 1520 23.0 ˚C 7 th Floor 25TR 4 10778 24.0 ˚C 9 th Floor 40TR 7 6547 6230 12140 Air Volume (CFM) 23.0 ˚C 21.5 ˚C 21.5 ˚C Return Air Temperature 9 th Floor 25TR 8 6 th Floor 25TR 2 6 th Floor 40TR 1 Particulars #

8. Audit Scope of Work Capacity vs. Utilization Chiller Plant AHU Chiller Water Pump Motor Cooling Tower Cooling Water Pump Motor Pipeline Facility Observations and Recommendations Temperature Readings and Analysis Conclusions and Next Steps Agenda

9. Maximum Consumption of Cooling System Cooling System COP/EER Chiller Plant 2x140TR Cooling Towers 2x140TR Chiller Plant Water Motor 3x12.5 HP AHU (292 TR) 4x40TR, 4x25TR,10TR Current: 178TR Current: 140TR Current: 2x140TR Current: 2x12.5HP Current: 38.5TR 3  Split A/C 2x8TR, 1x7.5TR, 2x5.5TR Cooling Tower Pump Motors 3x12.5 HP Current: 2x12.5 HP

10. Capacity vs. Utilization Chiller Plant (Electrical) Chiller Plant Utilization = 90.8/101 = 90% There are 2x140TR chiller plants, with only one at a time operating Considering 1TR = 0.65kW for water-cooled chiller, 90.8 TOTAL 095 0.92 0.87 PF 130.75 155.96 183.47 Current (A) 29.22 234 B 33.83 235 Y 37.75 236 R kW Voltage (V) 140TR

11. Capacity Vs Utilization 140 TR Chiller Chiller TR = Factor x Water Flow Rate x (Tin – Tout)/12000 = 500 x 840 x (50 - 47)/12000 = 105 TR Installed capacity is 140 TR and consumption is 105 TR Utilization = 105/140 = 75% Chilled Water Flow Rate: 840 US GPM 47.0°F 50.0°F Water Temperature 8.4°C 10.0°C Water Temperature Chiller outlet temperature 2 Chiller inlet temperature 1 Particulars 140TR

12. Capacity vs. Utilization AHU (6 th Floor A and B wing) 6 th Floor South AHU Utilization = 2.60/7.24 = 35.9% 6 th Floor North AHU Utilization = 1.6/4.5 = 35.6% Considering (COP) 1TR =0.181 kW for AHU, 2.60 TOTAL 0.57 0.60 0.55 PF 5.65 5.65 5.73 Current (A) 1.01 236.1 B 0.86 234.3 Y 0.73 235.0 R kW Voltage (V) A-wing 1.61 TOTAL 0.36 0.39 0.38 PF 6.10 6.13 6.04 Current (A) 0.52 232.2 B 0.56 232.7 Y 0.53 232.0 R kW Voltage (V) B-wing

13. Capacity vs. Utilization AHU - CFM (6 th Floor A and B wing) TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 12140 X(29-22)/12000, = 31.5 TR Installed capacity is 40TR and consumption is 31.5TR,% of utilization = 31.5/40 = 78.5% TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 6230X(36.5-28)/12000 = 19.63 TR Installed capacity is 25TR and consumption is 20TR, % of utilization = 19.63/25 = 78.5% Enthalpy difference (Hin and Hout ) is obtained from psychrometric chart 17.5 ˚C DBT 17.0 ˚C WBT 12.0 ˚C DBT 11.5 ˚C WBT Leaving Air Temperature 6230 12140 Air Volume (CFM) 26.5 ˚C DBT 22.0 ˚C WBT 21.5 ˚C DBT 16.0 ˚C WBT Enter Air Temperature 6 th Floor 25TR 2 6 th Floor 40TR 1 Particulars #

14. Capacity vs. Utilization AHU (7 th Floor A and B wing) 7 th Floor South AHU Utilization = 1.95/4.5 = 43% 7 th Floor North AHU Utilization = 2.08/7.24 =29% Considering ( COP) 1TR = 0.181 kW for AHU, 1.95 TOTAL 0.46 0.52 0.50 PF 5.76 5.59 5.39 Current (A) 0.63 234.6 B 0.68 233.2 Y 0.64 231.2 R kW Voltage (V) B-wing 2.08 TOTAL 0.45 0.47 0.45 PF 6.67 6.43 6.38 Current (A) 0.71 234.6 B 0.71 232.9 Y 0.66 230.2 R kW Voltage (V) A-wing

15. Capacity vs. Utilization AHU - CFM (7 th Floor A and B wing) TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 12253 X(31.5-25.5)/12000, = 27.3 TR Installed capacity is 40TR and consumption is 27.3TR ,% of utilization = 27.3/40 = 68.25% TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 1520 X(31.0-24.0)/12000, = 5.7 TR Installed capacity is 25TR and consumption is 5.7TR ,% of utilization = 5.7/25 = 22.8% Enthalpy difference (Hin and Hout ) is obtained from psychrometric chart 13.5 ˚C DBT 13.0 ˚C WBT 15.5 ˚C DBT 15.0 ˚C WBT Leaving Air Temperature 1520 12253 Air Volume (CFM) 23.0 ˚C DBT 17.5 ˚C WBT 22.5 ˚C DBT 18.0 ˚C WBT Enter Air Temperature 7 th Floor 25TR 2 7 th Floor 40TR 1 Particulars #

16. Capacity vs. Utilization AHU (8 th Floor A and B wing) 8 th Floor South AHU Utilization = 1.29/4.5 = 29% 8 th Floor North AHU Utilization = 1.66/7.24 = 23% Considering (COP) 1TR = 0.181 kW for AHU, 1.29 TOTAL 0.40 0.44 0.37 PF 4.62 4.63 4.45 Current (A) 0.44 234.4 B 0.48 234.5 Y 0.37 232.7 R kW Voltage (V) B-wing 1.66 TOTAL 0.36 0.36 0.40 PF 6.10 6.47 6.40 Current (A) 0.52 233.2 B 0.54 234.1 Y 0.60 233.1 R kW Voltage (V) A-wing

17. Capacity vs. Utilization AHU - CFM (8 th Floor A and B wing) TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 10778 X(31.5.0-24.5)/12000, = 26TR Installed capacity is 40TR and consumption is 26TR ,% of utilization = 26/40 = 65% TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 6992 X(30-24.0)/12000, = 15.56 TR Installed capacity is 25TR and consumption is 16TR ,% of utilization = 15.56/25 =62.3% Enthalpy difference (Hin and Hout ) is obtained from psychrometric chart 14.5 ˚C DBT 13.0 ˚C WBT 14.0 ˚C DBT 14.0 ˚C WBT Leaving Air Temperature 6992 10778 Air Volume (CFM) 22.0 ˚C DBT 17.0 ˚C WBT 23.0 ˚C DBT 17.5 ˚C WBT Enter Air Temperature 8 th Floor 25TR 2 8 th Floor 40TR 1 Particulars #

18. Capacity vs. Utilization AHU (9 th Floor A and B wing) 9th Floor South AHU Utilization = 2.98/7.24 = 41% 9th Floor North AHU Utilization = 1.74/4.5 = 39% Considering (COP) 1TR = 0.181 kW for AHU, 2.98 TOTAL 0.54 0.60 0.53 PF 7.74 7.79 7.59 Current (A) 0.98 234.7 B 1.10 233.6 Y 0.90 232.7 R kW Voltage (V) A-wing 1.74 TOTAL 0.18 0.50 0.69 PF 5.14 7.21 5.00 Current (A) 0.21 228.9 B 0.84 229.2 Y 0.79 226.8 R kW Voltage (V) B-wing

19. Capacity vs. Utilization AHU - CFM (9 th Floor A and B wing) TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 10778 X(31.5-25.5)/12000, = 40 TR Installed capacity is 40TR and consumption is 39.96TR ,% of utilization = 40/40 = 99.9% TR for AHU = Factor X Air flow X (Hin – Hout) Enthalpy difference/12000 = 4.45 X 6547 X(31.5-25.0)/12000, = 15.8 TR Installed capacity is 25TR and consumption is 16TR ,% of utilization = 16/25 = 64% Enthalpy difference (Hin and Hout ) is obtained from psychrometric chart 16.0 ˚C DBT 14.0 ˚C WBT 15.0 ˚C DBT 14.0 ˚C WBT Leaving Air Temperature 6547 10778 Air Volume (CFM) 23.0 ˚C DBT 18.0 ˚C WBT 24.0 ˚C DBT 22.5 ˚C WBT Enter Air Temperature 9 th Floor 25TR 2 9 th Floor 40TR 1 Particulars #

20. Audit Scope of Work Capacity vs. Utilization Chiller Plant AHU Chiller Water Pump Motor Cooling Tower Cooling Water Pump Motor Pipeline Facility Observations and Recommendations Temperature Readings and Analysis Conclusions and Next Steps Agenda

21. AHU (6 th Floor) Observations A/C mounted on top of battery rack

22. AHU (6 th Floor) Observations and Recommendations Observations A/Cs mounted on top of UPS and battery racks; drain water from A/C may enter the UPS Recommendations Shift the A/Cs to different locations in the room to avoid disaster caused by drain water and shock from the body

23. 3TR AHU (6 th Floor) Observations Permanent wires disconnected Temporary wires connected

24. 3TR AHU (6 th Floor) Observations No air filter

25. 3TR AHU (6 th Floor) Observations Unprofessional way of routing No earth connection

26. 3TR AHU (6 th Floor) Observations Filter not removable

27. AHU (6 th Floor) Observations and Recommendations Observations Split is powered with temporary wires Working without filters No earth connection to split Unable to remove the filter Recommendations Remove Temporary cables Install filters Ensure the earth connection Ensure filter is removable

28. 25 TR AHU (6 th Floor, B-wing) Observations AHU with no filter

29. No air filter 25 TR AHU (6 th Floor, B-wing) Observations Fins damaged

30. 25 TR AHU (6 th Floor, B-wing) Observations and Recommendations Observations No air filter for AHU; dust particles will enter facility Recommendations Install air filter

31. AHU Condensing Grills (6 th Floor) Observations Condensing grill got damaged Fins damaged

32. AHU Condensing Grills (6 th Floor) Observations and Recommendations Observations AHU condensing grills are damaged Recommendations Replace condensing grills

33. AHU Room (6 th Floor, B-wing) Observations All unwanted materials exist in room

34. AHU Room (6 th Floor, B-wing) Observations Unwanted materials near pipeline Rusted meter tube Dust and dirt deposited on meter

35. AHU Room (6 th Floor, B-wing) Observations Unnecessary cables at AHU

36. Drying pipe blocked AHU Room (6 th Floor, B-wing) Observations

37. AHU Room – 6 th Floor (B-wing) Observations and Recommendations Observations Unwanted materials exist Meter tube is rusted and inaccessible Unused cables exist Drying pipe is blocked, leading to water inside the AHU Recommendations Remove the unwanted materials Clean and paint the meter tube Provide sufficient space to access the meter tube Remove unused cables Clear the drying pipe

38. Thermo Control Valve (6 th Floor, B-wing) Observations Damaged thermo control valve Missing 3 way mixing valve motor

39. Thermo Control Valve (6 th Floor, B-wing) Observations and Recommendations Observations Thermo control valve is damaged Recommendations Replace the damaged thermo control valve

40. Cafeteria (6 th Floor) Observations No partition between cafeteria and wash room Exhaust fan sucking cool air

41. Cafeteria (6 th Floor) Observations Open windows with A/C running

42. Cafeteria (6 th Floor) Observations and Recommendations Observations Wash room exhaust fan sucking cool air out from the cafeteria No partition between wash room and cafeteria Window is opened Recommendations Provide partition between cafeteria and wash room Close the window

43. Chilled Water Line (8 th Floor) Observations Gap on chilled water line

44. Chilled Water Line (8 th Floor) Observations and Recommendations Observations Gaps along the chilled water line Recommendations Fill the gaps

45. Chiller Plant Motor Starters (Terrace) Observations Seepage Starter enclosures in poor condition Pipeline too close to starters

46. Chiller Plant Motor Starters (Terrace) Observations and Recommendations Observations Seepage on walls No proper enclosures for motor starters Pipeline adjacent to starters Recommendations Avoid seepage Install proper enclosure Shift the pipeline or take necessary precautions

47. Chiller Plant Pumps (Terrace) Observations Pump rusted No proper enclosure on motor Seepages

48. Chiller Plant Pumps (Terrace) Observations Pumps rusted No enclosure at termination Seepages

49. Chiller Plant Pumps (Terrace) Observations Dust and dirt on the floor Termination box open Leakage

50. Chiller Plant Pumps (Terrace) Observations and Recommendations Observations No general maintenance to pumps; led to rust No proper enclosure on motors and pumps; motor electrical terminators are open Seepage on floor Floor not clean Recommendations Clean and paint rusted areas and implement maintenance Ensure proper enclosures Avoid seepage Keep the floor clean

51. Chilled Water Pipes (Terrace) Observations Pipes rusted

52. Chilled Water Pipes (Terrace) Observations and Recommendations Observations Condensation pipes got rusted Insulation on pipe line is damaged Recommendations Clean and paint the rusted areas Do proper insulation wherever it is damaged

53. Chiller Plant Panel (Terrace) Observations Panel got rusted

54. Chiller Plant Panel (Terrace) Observations and Recommendations Observations Panel rusted No proper routing and dressing inside the panel Recommendations Clean panel and paint it to protect from rust Do proper dressing

55. Chiller (Terrace) Observations and Recommendations Observations All the water flow measuring gauges are not working All thermometer not working Buttery fly valves are jammed Recommendations Preventive maintenance is required for all water gauges Preventive maintenance is required for thermometers; replace, if necessary Preventive maintenance is required for Butterfly valves, replace, if necessary

56. FRP Cooling Towers (Terrace) Observations and Recommendations Observations Water basin is getting rusted Butterfly and gate valves are not functioning properly Motor and fan supports are got rusted Recommendations Periodic cleaning required with chemical and water basin need to be paint with chemical protective Butterfly and gate valves needs servicing All supports needs painting

57. Condenser and Chilled Water Pumps (Terrace) Observations and Recommendations Observations All gauges and thermometers are rusted Butterfly and gate valves are rusted Pump sets and base frames are rusted Recommendations Replace all rusted gauges and thermometers Replace all rusted butterfly and gate valves Clean and paint rusted pump sets and base frames

58. AHU Observations Observations Siphon valve with punch cock is not working All pressure gauge meters for water flow measurement are rusted All thermometers are of 2” stem Pre filters are damaged Three way mixing valves are not functioning at AHU Missing of 3 way mixing valve motors and control cable Sedimentation inside the tube may obstruct the water flow Drain line jammed in 6 th floor 25TR AHU Fresh air damper not properly set to a have sufficient opening Air balancing is not their Cooling dampers not fitted properly Motor installed is 0f 12.5HP is over sized Butterfly valves are not functioning properly All the AHU are being under utilization AHU and AHU room covered with dust and dirt Fins are covered with pre filter hence it needs cleaning

59. AHU Recommendations Recommendations Siphon with punch cock to be replaced with stain less steel Replace rusted pressure gauges and thermometers All thermometer are to be replace with 4” stem for proper measurement Replace damaged pre filters Replace all three way mixing valves at AHU in lets Install 3 way mixing valve wherever it is missed Clean the cooling coils Clear the drain line Provide sufficient space for fresh air dampers at least 50% Balancing is required for uniform air distribution Fix the cooler damper properly Motor replace with proper size (10HP) Butter fly valves are to serviced and replace wherever it is necessary Recalibrate AHU sizing Clean AHU and AHU room

60. Pipelines Observations and Recommendations Observations Insulation on chilled water pipeline got damaged Water pipeline got rusted Recommendations Insulation need to carried out wherever it damaged All water pipelines needs painting

61. Audit Scope of Work Capacity vs. Utilization Chiller Plant AHU Chiller Water Pump Motor Cooling Tower Cooling Water Pump Motor Pipeline Facility Observations and Recommendations Temperature Readings and Analysis Conclusions and Next Steps Agenda

62. Chiller Plant Bus Bar Temperature Reading Forced air cooling is required inside the panel

63. Audit Scope of Work Capacity vs. Utilization Chiller Plant AHU Chiller Water Pump Motor Cooling Tower Cooling Water Pump Motor Pipeline Facility Observations and Recommendations Temperature Readings and Analysis Conclusions and Next Steps Agenda

64. Conclusions and Next Steps Chiller plant is under provisioned Actual chiller required for heat load is 178 TR whereas available capacity is 140TR; in summer, both chiller plants must be operated at the same time to get sufficient cooling Increase chiller TR; as the PSI is high, compressor is getting overstrained and the compressor motor is taking more current than necessary; this reduces the life of the compressor Cooling tower usage is not appropriate Only one chilled water pump, cooling tower and cooling tower water motors have to be used per one chiller plant; there are two cooling towers and water motors being used with one chiller plant currently; this leads to greater electrical consumption, it does not help with cooling either Running of both the cooling towers 24/7 is also a problem

65. Conclusions and Next Steps AHU is over provisioned Total AHU required for existing load is178TR; installed capacity is 292TR; only 9th floor AHU running at100%; others under-utilized 40TR AHU blower motor capacity is 12.5HP; required is 10HP All 3-way mixing valves are not functioning; no control on chilled water plant leads to greater electrical consumption and reduces cooling effect With the 3-way mixing valves not functioning, we cannot bring the chilled water outlet temperature down to 6 degrees Do not change to air cooling The advantage of water cooled HVAC is that it consumes less electrical power and has no environmental pollution as against an air cooled one. Implement a maintenance regime to lower the running costs and total cost of ownership of the HVAC system

66. Choice Solutions Contacts Ramesh R. Senior Solutions Architect, NCPI Choice Solutions, Chennai [email_address] Cell: +91 98410 05183 Tel: +91 44 2436 3391/92/93 http://www.choice-solutions.com Srinivas Chowdary Senior Solutions Architect, NCPI Choice Solutions, Hyderabad [email_address] Cell: +91 98660 79498 Tel: +91 40 2354 7600 http://www.choice-solutions.com