This document summarizes the development of Malaysia's first remote satellite chilled water storage system for district cooling in Putrajaya. The 100,000RT chilled water storage tank at Gas District Cooling Plant #4 will allow Plant #2 to charge chilled water overnight using excess capacity, and both plants can discharge chilled water during peak daytime loads. This innovative approach reduces electricity costs and demand, increases the cooling supply capacity of the system, and leads to better utilization of assets to reliably meet the growing cooling needs of Putrajaya's core island area.
AWS Community Day CPH - Three problems of Terraform
Development of the Malaysia’s first satellite remote charging District Cooling Plant at Precinct #4 Putrajaya, Malaysia
1. ASIAN DEVELOPMENT BANK
SOUTHEAST ASIA ENERGY EFFICIENCY INITIATIVE
ENERGY WISE-EXPLORING PROSPECTS FOR DISTRICT COOLING IN
SOUTHEAST ASIA
PUTRAJAYA
22 OCT 2013
DEVELOPMENT OF THE MALAYSIA’S FIRST SATELLITE REMOTE CHARGING
100,000RTH CHILLED WATER STORAGE SYSTEM AT GAS DISTRICT COOLING
(GDC) PLANT #4 AT LOT 4U2, PRECINCT 4,
PUTRAJAYA CORE ISLAND
BY
IR. ARUL HISHAM BIN ABDUL RAHIM
BSME, P.Eng, MIEM, MASHRAE, MACEM
PRINCIPAL
AHAR Consultants
3. NEEDS STATEMENT
UTILISATION OF PLOT 4U2 FOR FUTURE COOLING LOAD OF 22,000
RT FOR CORE ISLAND OF PUTRAJAYA FROM TES TANK WITH SPACE
RESERVED FOR FUTURE EXPANSION
FULL UTILISATION OF GAS TURBINE AND EQUIPMENT FROM PLANT
#2 AND TO REMOTELY CHARGE TES TANK AT PLANT #4
COOLING LOAD GROWTH IS ASSUMED 3,000 RT PER YEAR
MINIMISE ELECTRICAL POWER IMPORT FROM TNB DURING PEAK
PERIOD
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7. LOAD PROJECTION @ CORE ISLAND
RT
Capacity Planning
4,000RT/yr growth
3,000RT/yr growth
2,000RT/yr growth
120,000
Growth Projection from
Capacity
Planning Study
100,000
80,000
Historical Growth is ~ 3,650 RT per year
based on 22,000 RT between yr 2003 to
2009
60,000
40,000
30,000
20,000
Current Planting-up ; TES Tank
or
Electrical Driven Chiller
Max 22,000 RT
2011
2012
2013
2014
2015
2016
2017
2018
Future
2019
2020
2021
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2022
2023
2024
2025
2026
2027
2028
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8. SNAPSHOT OF LOAD PROFILE CORE ISLAND– MARCH 2009
PEAKING
PULL DOWN
LOAD
LOW NIGHT LOAD
BUILDINGS START
OPERATION
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9. PLANT #2 EQUIPMENT
Equipment
Quantity
Generating
capacity (RT)
Firm Generating
Capacity (RT)
STEAM
ABSORPTIONCHILLER
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
∑ = 30 200 RT
Installed capacity
Firm Capacity
Plant Generation Ratio
: 32 700 RT
: 30 200 RT
= 92.3 % of installed capacity
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10. THE SOLUTION
PLANT #2 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 PLANT
#2.
A SATELLITE STRATIFIED CHILLED WATER STORAGE SYSTEM WAS
SELECTED TO BE INSTALLED AT PLANT #4 SITE TO STORE THE CHILLED
WATER GENERATED FROM PLANT #2 DURING OFF-PEAK PERIOD.
OPERATE PLANT #2 AT NIGHT TO STORE CHILLED WATER AT PLANT #4
OPERATE PLANT #2 AND PLANT #4 DURING DAYTIME TO MEET COOLING
LOAD
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12. P L A N E Q U I P M E N T L AYO U T ( U LT I M AT E )
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13. PLANT ISOMETRIC PIPING
( I N I T I A L P H A S E W I T H C H W S TO R A G E TA N K S )
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14. P L A N T I S O M E T R I C P I P I N G ( U LT I M AT E P H A S E )
C H W S TO R A G E TA N K S A N D E L E C T R I C C H I L L E R S
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15. BASIC CHW TANK OPERATION
CHARGING MODE
WARM WATER
THERMOCLINE
COLD WATER
PIPE OUT
PIPE IN
DIFFUSER PIPE
SYSTEM
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16. BASIC CHW TANK OPERATION
DISCHARGING MODE
WARM WATER
THERMOCLINE
COLD WATER
PIPE IN
PIPE OUT
DIFFUSER PIPE
SYSTEM
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22. BENEFITS
40% OF PEAK
LOAD BY TES
4 MW
(RM 154k
/MO)
LESS CHILLERS
OPERATE AT
PEAK
LOAD
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23. PARTING WORDS
DISTRICT COOLING AND THERMAL STORAGE:
EXCELLENT TOOL FOR DEMAND SIDE MANAGEMENT
REDUCTION IN ENERGY COST
REDUCTION OF ELECTRICITY MAXIMUM DEMAND @ PEAK
PERIOD
INCREASE THE LOAD SUPPLY CAPABILITY AND ENHANCE THE
RELIABILITY AND AVAILABILITY OF THE CHILLED WATER
SYSTEM.
IMPROVES REDUNDANCY OF THE SYSTEM AS LESS EQUIPMENT
IS REQUIRED TO BE RUN DURING PEAK PERIOD
BETTER UTILIZATION OF ASSETS
GDC PUTRAJAYA PLANT #4 :
IS THE FIRST REMOTE SATELLITE(2KM) CHARGING CHILLED WATER
STORAGE SYSTEM PLANT IN MALAYSIA
HAS THE BIGGEST CONCRETE CHILLED WATER TANK IN MALAYSIA;
AND PERHAPS IN ASIA.
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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. Plant #2, commissioned in 2003; designed primarily to serve Precinct 2, was extended to provide cooling to Precinct 3 and Precinct 4.
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.
Shown above is a typical weekday cooling load profile of the Core Island. As can be seen above, the buildings start operation of the air side at about 6am. From 6 to 8 am, that is where the maximum pull down load occurs. This load can be as high as 20% of the average load. There is very little night load as these buildings are all government offices.
Plant #4 was planned as a hybrid plant consisting of chilled water storage and chillers. The construction of the plant is phased. For Phase 1, we install 1 unit of chilled water storage tank of nominal rated capacity of 100,000 RTh with associated booster pumpsFor 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
These are the photo after the filling up of the tank. Our 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. The bottom picture is the connection pipe 1.2m diameter to the main network pipe.
Peaking morning pull down load is taken up by Plant #4 without having to run additional chillers from Plant #2. This has reduced the quantity of chillers required to meet the demand; hence, enhancing the reliability and availability of the overall system.Plant #4 is currently discharging about 40% of the peak period load demand. Currently, Plant #2 is supplying about 15,000RT and Plant #4 supplies averaging 10,000RT. Plant #4 also reduces the TNB electricity import of Plant #2 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.
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. In the case of Plant 4, assets utilization is improved as the machines are run day and night and not subjected to frequent start/stop operation.This GDC Plant 4 has made history as it is the 1st remote charging satellite chilled water storage tank in the country. Also, we believe this concrete tank is the biggest concrete tank for chilled water storage in Malaysia and perhaps in Asia.