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Publisher’s Letter

Publisher Pravita Iyer [email protected]

Hello and welcome once again to Cooling India. In the past 50 years, protecting the global environment has emerged as one of the major challenges in international relations. Every year on 5th of June, the world unites together to spread global awareness about various environmental concerns and bring about positive changes to protect our planet. As I write this note, there is news that the High Court in Maharashtra has upheld the ban on plastics. That means, no manufacturing of plastics can take place after 3 months from now.

Editor-in-Chief Mahadevan Iyer [email protected]

Publications worldwide, including this one, use plastic envelopes to send the magazines to their respective subscribers. We will need to find an alternate as well. That is saving our environment from the hazards that pose from use of plastics. What about the problems of environment posed by the HVACR industry?

Subscription Department Priyanka Alugade [email protected]

Refrigerants make air conditioning possible. These liquid agents cool and dehumidify indoor air. For years, the most common refrigerant gas used in air-conditioning systems was R-22, which in the past was viewed as a safe refrigerant, but it depletes the ozone layer and the industry is aware of this and some have taken steps to find replacements but others have been slow to react. The Montreal Protocol on Substances that Deplete the Ozone Layer is one of the most recognized and acclaimed international environment treaty in history, under which India has already successfully phased out the earlier generation of refrigerants viz., CFCs. The country is currently phasing out the HCFC in a gradual manner and then the next step would be to cut use of HFC by nearly 80% and ultimately phase out HFC in the next 30 years. Manufacturers will have to use refrigerants that are balanced like for example R-32 which has a global warming potential of 675, which is three times lower than R410A. Also systems running on natural refrigerants CO2, ammonia or hydrocarbons have little or no global warming potential if the refrigerant is released into the atmosphere.

Subscribing Cooling India is now a click away Just llog on to www.coolingindia.in

Directors Mahadevan Iyer Pravita Iyer

Hope you enjoy reading this issue as much as we have in bringing this to you. Do send in your comments to me at pravita@ charypublications.in

Pravita Iyer

Publisher & Director

4 | Cooling India | April 2018

Associate Editor Supriya Oundhakar [email protected] Advertising Manager Nafisa Kaisar [email protected] Design Nilesh Nimkar [email protected]

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www.facebook.com/coolingindiamagazine www.linkedin.com/in/coolingindia www.twitter.com/coolingmagazine Disclaimer: Chary Publications does not take responsibility for claims made by advertisers relating to ownership, patents, and use of trademarks, copyrights and such other rights. While all efforts have been made to ensure the accuracy of the information in this magazine, opinions expressed and images are those of the authors, and do not necessarily reflect the views/collection of the owner, publisher, editor or the editorial team. Chary Publications shall not be held responsible/ liable for any consequences; in the event, such claims are found - not to be true. All objections, disputes, differences, claims and proceedings are subject to Mumbai jurisdiction only. Printed by Pravita Iyer and Published by Pravita iyer on behalf of Chary Publications Pvt Ltd., and Printed at Print Tech, C-18, Royal Ind. Est., Naigaum Cross Road, Wadala, Mumbai 400031 and Published at 906, The Corporate Park, Plot 14&15, Sector - 18, Vashi, Navi Mumbai - 400 703. . Editor: Mahadevan Iyer

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Contents Articles Health, Comfort, Efficiency – Three Dimensions of Building Performance

Vol. 13 No. 9 | April 2018

Interviews “We just don’t provide instruments but we explore, develop solutions”

22

– Ashish K Jain

Towards Efficient Compressors

28

– Dr S S Verma

Compressor in Refrigeration System

Kalidas Bhangare

40

Managing Director, Testo India Pvt. Ltd.

– Bijan Kumar Mandal, Madhu Sruthi Emani, Shounak Chowdhury

Mechanical Hazards of Refrigeration Equipment 46 – C Maheshwar

Post-harvest Handling & Storage of Potato

56

– Mahesh Kumar, BVC Mahajan, Ritu Tandon

Energy Loss in AHU

64

– S Ashok, K S Subramanian

Green Buildings: End User Perspective

70

– Anshul Pranay Gujarathi

Features 19 Sustainability Report Unveiled at Greenbuild 2017 21 Emerson Innovation Gets ACREX Award of Excellence 2018

27 Two BITZER Compressors Get ACREX Awards of Excellence

39 Dual Barrier Coating: Reducing Dust in ACs 45 LG Recognized for Sustained Environmental Leadership

53 First IoT Air Cooler 54 Delivering Environmentally Focused Installation 68 Renewable Energy Approach for Producing Ammonia


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Departments 4 Publisher’s Letter 8 News 16 Appointments 18 Awards 20 Market Watch 69 Statistics 72 Product Profile 73 Event Calender 73 Index to Advertisers 74 Cooling Museum

Fu Sheng Industrial Co. Ltd., Factory Add : 60, Sec. 2, Guangfu Rd., Sanchong, Dist. New Taipei City 24158, Taiwan, R.O.C. India Office: Mumbai, Maharashtra , E-mail - [email protected], Mobile: +91 7045611001

news Midea Becomes World’s First Blue Angel-Certified AC Manufacturer t Mostra Convegno Expo comfort (MCE) 2018, a leading international exhibition dedicated to comfort & living technology that kicked off on March 13 in Milan, Midea Group, the world leading home appliances manufacturer to celebrate its 50th anniversary this year, announced that its All Easy Series R-290 residential singlesplit air conditioner recently became the first of its kind being certified by the German ecolabel ‘Blue Angel’ for its ultralow global warming potential (GWP), high energy efficiency, low noise, and stringent material safety control.

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This event has a historic significance for the global air conditioner industry. It also makes Midea the world’s first in the industry to provide a mass-producible, efficient and reliable solution for the Kigali Amendment to the Montreal Protocol to phase down hydrofluorocarbons (HFCs). The Amendment is a common view of each country concerning the serious situation of global warming, and simultaneously it challenges the world air-conditioning industry. It has been an ultimate goal for each air-conditioning manufacturer to develop environmental and efficient products that reach the standard of this amendment. ‘Blue Angel’ certification, owned by the German Federal Ministry for the Environment, represents the highest standard for the comprehensive efficiency, healthy and environmental features of home appliances. If you use products or services holding the Blue Angel eco-label, you can be sure that you are doing something good for yourself, the environment and the future. 


Scientists Find Rapid Test for Legionella n an outbreak of Legionnaires’ disease, finding the exact source as quickly as possible is essential to preventing further infections. To date, a detailed analysis takes days. Researchers at the Technical University of Munich have now developed a rapid test that achieves the same result in about 35 minutes. Legionella are rod-shaped bacteria that can cause lifethreatening pneumonia in humans. They multiply in warm water and can be dispersed into the air via cooling towers, evaporative recooling systems and hot water systems. The most dangerous among the almost 50 species of Legionella is Legionella pneumophila. It is responsible for 80 percent of all infections. When an outbreak occurs, the source of the germs must be identified as soon as possible to prevent further infections. Similar to a paternity test, the origin of the outbreak is confirmed when the germs in the process water of a technical system exactly match those identified in the patient. However, often numerous systems must be tested in the process, and the

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requisite cultivation for the test takes around ten days. Meanwhile, there is a rapid test for detecting the Legionella pathogen in the clinic. It identifies compounds of Legionella in the urine of patients. “Unfortunately, this quick test serves only as a first indication and is not suitable for screening the water of technical systems,” says PD Dr. Michael Seidel, head of the research group at the Chair of Analytical Chemistry and Water Chemistry of the Technical University of Munich. The team of scientists, thus, developed a measuring chip in the context of the ‘LegioTyper’ project funded by the German Federal Ministry of Education and Research. 

Panasonic Factory in China Begins Mass Production anasonic Corporation has begun mass production of prismatic-type automotive lithium-ion batteries at its factory in Dalian, China, and held a ceremony to mark the first shipment recently. The market for eco-conscious vehicles, including hybrids, plug-in hybrids, and electric vehicles, is growing every year thanks to the increase in environmental awareness in recent years. To respond to the market demand, Panasonic has been gearing up to start production at this factory, which is its first production site for prismatic-type automotive lithium-ion batteries in China. Amidst expectations of expanding demand for automotive lithium-ion batteries, Panasonic manufactures the high-capacity and high-safety prismatictype batteries at this factory and ships them to the North American and Chinese

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markets. Shipments will be expanded in the future to reach more destinations, helping to drive the spread of eco-conscious vehicles. With the beginning of mass

production shipments of automobile lithium-ion batteries from this factory, Panasonic now has a production system covering Japan, the United States, and China, the three key global locations. By strengthening the global competitiveness of its automotive batteries with these sites, Panasonic will further expand its automobile battery business in the future. 

news

Cooling India | April 2018 | 9

news MEHITS Acquires Full Control of Topclima & Sater itsubishi Electric Hydronics & IT Cooling Systems Spa has acquired the minority shares of the distribution company Topclima and of the service company Sater. MEHITS already controlled both companies, where the heirs of the founders still maintained a minority share. With this move, MEHITS acquires 100% of ownership of both companies, hence, creating the conditions for further integrating Climaveneta distribution and service organisation with Mitsubishi Electric Europe, Spanish branch, in consistency with Mitsubishi Electric strategy in Europe.

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Electrolux Builds World’s First Bioplastic Concept Fridge lectrolux has developed a refrigerator prototype where all the visible plastic parts are made of bioplastics from renewable sources. The bioplastic for the refrigerator has a more than 80% lower carbon footprint compared to the conventional plastics used today. The prototype is the world’s first refrigerator made of bioplastic and part of Electrolux strategy to create more sustainable home appliances. Unlike ordinary plastics that are oil-based, bioplastics such as those used in the newly developed prototype refrigerator come directly from renewable resources, such as corn or sugarcane. The bioplastics used in the refrigerator are recyclable. The Electrolux Global Connectivity & Technology Center (GC&T) has explored and tested how bioplastics can be applied in Electrolux products and packaging. Together with the Electrolux Purchasing and R&D

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departments for food preservation, GC&T has successfully developed a refrigerator prototype where all the visible plastic parts are made of bioplastics. The material used in the refrigerator has been provided by NatureWorks, a world-leading supplier of biopolymers. The bioplastic for the refrigerator has 80% lower CO2 equivalent emissions compared to the conventional plastic used in current fridges. “We are very excited and proud to have developed the world’s first bioplastic concept fridge. Our ambition is to develop even more innovative, sustainable home appliances that we might see on the market in the future”, said Jan Brockmann, Chief Operations Officer at Electrolux. Electrolux has already committed to materials efficiency through the use of post-consumer recycled plastics, such as Carborec®, a plastic compound based on recycled polypropylene. 

Natural Refrigerant Process Chiller for Cereal Partners Worldwide TopClima employs 37 employees, has its head offices in Barcelona and local offices and service centres in Madrid and Valencia. It was established in Barcelona in 1994 as the official distributor and service centre for Climaveneta products. It rapidly gained a leadership position in chiller and heat pump distribution in the Spanish market, where TopClima was a pioneer in the adoption of Integra heat pumps for four pipe systems. This success is proven by more than 4500 units installed in Spain since 1994. Sater was established in 2008 as a dynamic service company specialised in service of AC systems. It operates mainly in the centre of Spain where it employs eight specialised engineers. After a transition period, the control and management bodies of both Topclima and Sater will be restructured to facilitate collaboration and synergies with Mitsubishi Electric Europe Spanish Branch. 


atural refrigerant cooling is now reaching into sectors outside of the retail area where its application is well established. An example of this wider application is illustrated by a recent Green Cooling project. The client, Nestle, has a sustainable and efficient approach to the use of refrigeration and cooling systems and, therefore, needed to source a process water chiller operating with a Natural Refrigerant. As such, Green Cooling were approached to propose a system for Cereal Partners, utilising a Natural Refrigeration system in order to provide process cooling to a new cereal mill. After reviewing the demands of the site and the cereal milling plant, a packaged CO2 water/Glycol Chiller was selected from the

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Green Cooling range. The system selected incorporated a buffer tank and primary or secondary circulation pumps in order to provide a cooling system that would meet the variable demands of the milling process. A free cooler was also provided as part of the package in order to deliver the maximum level of system efficiency. The whole system was designed around standard 33°C operating ambient conditions with the free cooler operating in low ambient conditions. Delivering the most sustainable and efficient natural refrigerant system was the priority on this project. However, specifying and selecting natural refrigerant process cooling systems is certainly not only the preserve of sustainably driven projects. 

news

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news Honeywell’s Indoor Navigation to Connected Building oneywell, a global leader in Connected Buildings, announced it has added new capabilities to the Honeywell Vector Occupant App that give occupants more control over their experiences within a building with the swipe of a screen. The most significant new feature is indoor navigation, which uses GPS-like technology to help users find their way around complex buildings that are difficult to navigate without directions. The benefits of the indoor navigation feature have been demonstrated in the Minneapolis Skyway System, a complex interlinked network of enclosed pedestrian walkways spanning 80 city blocks. The walkways protect Minnesotans from the harsh winter elements and summer humidity, allowing them to comfortably walk between more than 30 buildings in downtown Minneapolis. “For anyone who’s not a local, and for even some who are, finding your way around the skyway system can be a big challenge,” said Steve Cramer, President and CEO, Minneapolis Downtown Council. “With our initial use of the Honeywell Vector Occupant App, we’ve seen an immediate impact. The interactive map makes it really easy and intuitive to know exactly where you’re going, and how to get there.” In addition to the indoor navigation feature, the app also now includes a location-based feature to rate spaces, allowing those within a building to highlight comfort issues to building staff for quick resolution. Both features combine the convenience of today’s mobile devices with Internet of Things (IoT) building connectivity to help improve a user’s experience inside a building. “Much of a building’s success hinges on how happy and satisfied its occupants are. They’re the lifeblood of an organization, and their experience within a building is what keeps them coming back,” said Aseem Joshi, Country General Manager, Honeywell Building Solutions, India. 

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NewCold Looks for Additional Premises ewCold UK is looking at possibilities for a new site to accommodate increased UK market activity and in anticipation of the demand expected to be triggered by the ‘Brexit effect’ in European Supply Chains. According to NewCold Country Director Jon Miles, the movement of goods from central European hubs into the UK will become more complex, based on the likelihood that we will leave the Customs Union and the impact that will have on Supply Chains. “Currently, it is possible for a food producer to store product in a warehouse close to the coast in Belgium or France and deliver directly into UK Distribution Centres within acceptable lead times. However, a recent study by Imperial College London has indicated that even an additional 2-minute stop at customs checkpoints could lead to the final 40 miles of the journey to the Channel Tunnel taking five hours. The time and risk associated with these increased journey times will mean that the most obvious solution is to store the products closer to the market in the UK.”

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NewCold has already bolstered its UK deep-frozen storage and handling capability with the addition of 600,000 cubic metres of fully automated deepfrozen capacity to its Wakefield site and expects to be fully operational by April 2018. “Frozen food handling in the UK is already in peak demand,” adds Jon “and we have developed the Wakefield facility in line with the projected long-term requirements of our key customers, and positive market outlook. Kantar World panel reported volume up by 2% in 2018, and this annual growth is expected to continue for at least the next 5 years. Phase two of the Wakefield site expansion lifts our capacity to 1,43,000 pallets but even so, we expect to be 70% full by June 2018. Add this to the increase in storage demand which is likely to be caused by Brexit and it is clear to see why we need to make provision for an additional UK facility.” NewCold’s vehicle fleet, which includes auto-loading double-deck trailers, has also been recently increased to 50 tractor units and 75 temperature-controlled trailers. 

Fujitsu & Ventacity Offer HVAC Solution for Smart Buildings ujitsu General America has partnered with Portland, OR-based Ventacity Systems to provide a more efficient heating, cooling, ventilation and controls solution for commercial buildings. The joint solution combines Ventacity’s energy-efficient ventilation and the company’s newly-introduced Ventacity HVAC 2 Smarter Building Platform wholebuilding controls technology with Fujitsu’s full line of Airstage VRF heating and cooling systems. The two systems, working together seamlessly, enhance comfort, provide better zoning and create a healthier indoor environment. The plug-and-play integration between the Airstage system and Ventacity’s cloudenabled, heat recovery ventilator (HRV) effectively lowers the variable refrigerant flow (VRF) capacity needed in order to keep buildings at set point temperatures while ventilating per ASHRAE 62.1. The addition

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of Ventacity’s HVAC 2 platform adds a cloud-based system that helps costeffectively monitor and manage HVAC systems in a single building or across entire building portfolios, capturing vital building analytics that can optimize the system’s performance. The packaged solution will be attractive to design-build contractors and engineers who focus on small- to medium-sized commercial buildings while searching for efficient, sustainable, low carbon emission solutions. “Our partnership with Fujitsu will take the HVAC industry into the 21st century, and, for the first time, enable HVAC contractors to apply modern cloud based technology and simple automated processes to provide commercial buildings with a healthier, more efficient, and more smartly managed environment,” said Sal D’Auria, founder and CEO, Ventacity Systems. 

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news Screw Compressor Market worth USD 11.01 Billion by 2021 he screw compressor market is expected to grow from an estimated USD 7.99 billion in 2016 to USD 11.01 billion by 2021, at a CAGR of 6.62%. The global market is set to witness significant growth, due to the increasing demand for energy-efficient compressors and low maintenance and operation costs of screw compressors. The single-stage segment is expected to hold the largest share of the screw compressor market, by stage, during the forecast period. The single-stage segment led the screw compressor market in 2015 and is expected to grow at the fastest rate during the forecast period, owing to the increasing demand for screw compressors in industries where process needs continuous high air quality in a shorter downtime. These compressors are more suitable for industries such as petrochemicals, mining, and oil & gas as they help in maintaining continuous and uninterrupted operations. Food & beverage to be the fastest growing end-user segment during the forecast period: With regard to the end-user segment, food & beverage segment is expected to

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be the fastest growing market in 2016. The food & beverage end-user needs 100% pure oil-free air for processing food. There might be a risk of contamination if the compressed air contains any external particle in the output. Therefore, oil-free screw compressors are used in this industry in order to maintain air quality standards. Asia-Pacific: The fastest growing market for screw compressor The screw compressor market has been analyzed with respect to five regions, namely, Asia-Pacific, the Middle East & Africa, Europe, North America, and Latin America. Asia-Pacific is expected to dominate the global screw compressor

market, owing to increasing industrialization and manufacturing facilities in the region. China is expected to dominate the screw compressors market in the Asia-Pacific region. To enable an in-depth understanding of the competitive landscape, the report includes profiles of some of the top players in the screw compressor market. These players include Atlas Copco AB (Sweden), Ingersoll Rand PLC (Ireland), GE Oil & Gas (UK), Gardner Denver, Inc. (US), and Siemens AG (Germany). Leading players are trying to penetrate the markets in developing economies, and are adopting various strategies to increase their market share. 

Chemours Purchases Refrigerant Manufacturer ICOR long with Honeywell, Chemours is one of the largest refrigerant manufacturers, producers, and researchers in the world. Chemours has made a new acquisition. Chemours purchased a much smaller company out of Indiana known as ICOR International. ICOR is an innovator in the refrigerant world. Instead of making due with the status quo during all of these phase downs and phase outs they took it upon themselves to come up with alternative refrigerants that could be used in existing machines and that would also be environmentally friendly. ICOR supplies a range of HFC refrigerants – R134a, R407A, R404A, R407C, R410A – as well as the hydrocarbons propane and isobutane. In addition it supplies a number of specialist

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blends NU-22B (R422B), Hot Shot-2 (R417C) and One Shot-C (R422C). All contain varying proportions of R125 and R134a with a small amount of hydrocarbon and are designed to replace a range of refrigerants including R22. “ICOR has developed an excellent

reputation with contractors and equipment owners, has strong brands and an extensive distributor network, all of which will be a valuable addition to Chemours and enhances our ability to meet our customer needs in North America,” said

Diego Boeri, vice president of Chemours fluorochemicals business. “Chemours is establishing itself as a new kind of chemistry company and we are excited to join them on this journey,” said Gordon McKinney, vice president of sales and COO of ICOR International. ICOR International was originally known as Indianapolis Refrigeration and in 1995 they incorporated and changed their name to ICOR International. They got their start at around the time the R-12 phase out had begun. When the R-12 phase down began in the early 1990’s all of this was new. It was the first major phase down of a refrigerant and there just weren’t a lot of solutions or alternative options out there. Around this same time ICOR developed their own R-12 refrigerant known as ‘Hot Shot.’ 

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appointments David Frise Appointed BESA Chief Executive avid Frise has been appointed as lot in common with the nuclear the new Chief Executive Officer industry. “We may not have the same of the Building Engineering profile, but should give ourselves a bit Services Association (BESA). He has more credit. It will be part of my been combining the roles of head of mission to impress on anyone who sustainability at BESA and chief will listen that building engineering has executive of the construction fit-out a vital social and economic role to play body FIS for seven years. He takes over by helping to deliver a top quality built as CEO of BESA with immediate effect, environment.” He is a frequent speaker on a range but will also continue in his role at the David Frise of industry topics including energy FIS for a short period to help manage efficiency, system integration, the transition to his successor. A former nuclear submariner, he left the Royal Navy to government policy and the ‘performance gap’ in buildings. “We become Managing Director of a building engineering services are delighted to have secured David’s services,” said BESA contractor, which he described as a “logical step”. “Submarines President Tim Hopkinson. “He is a well-known and respected and buildings might look like two different worlds, but in the end industry figure, who brings enormous experience to the role. He it’s all plumbing!” he said. “That doesn’t mean any of it is easy, also brings vital continuity, as an existing senior member of staff but the basic engineering principles are the same and good and former md of a member company, along with a fresh  quality building services firms – like BESA members – have a perspective thanks to his time leading the FIS.”

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Hubbard Makes Three New Appointments ubbard Products has 30-year career includes strengthened its engineering and management commercial refrigeration proficiency gained at City capabilities with three new Refrigeration. appointments. Dougie Stoddart Steve Feeney becomes - Commercial Director explains, Applications Engineer “Hubbard has a reputation -Technical back up, moving Brian Clark Steve Feeney Francis Wallace gained over 50 years for from Regional Sales Manager delivering value-for-money Scotland & Ireland. refrigeration solutions for its growing market of retail and Francis Wallace is appointed Commissioning Technology manufacturing customers. Manager, to support customers with technical back-up during Brian Clark is appointed Regional Sales Manager covering commissioning including troubleshooting and aiding the design Scotland and the North of England to the M62 corridor. A senior department in the development of innovative products with  engineer with considerable commercial experience, Brian’s practical application knowledge.

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Ian Carroll is Fujitsu COO an Carroll has been appointed chief operating officer of Fujitsu General Air Conditioning (UK). He was previously Sales and Marketing Director and joined Fujitsu in 2014. He completed two years as Sales Director at the now defunct Fujitsu distributor Wave Air Conditioning. Prior to that, he was national sales manager at refrigeration and air conditioning wholesaler Climate Center and spent three years there. Since joining Fujitsu, Ian Caroll has made a significant contribution to the company’s growth and its UK market share. In his new role, he will

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Ian Carroll

take full control of all aspects of the UK business, reporting to the Fujitsu General Air Conditioning (UK) board of directors. Commenting on the new role, he said, “I have seen the company go from strength to strength, especially in terms of developing technologically advanced products. We have already made great strides in growing our position in the UK air conditioning market – and I am looking forward to the next few years, as we work towards achieving further success.” 

appointments


awards

Daikin India Receives Most Energy Efficient Air Conditioners Award aikin is one of the top most companies in the air conditioning industry. The history of Daikin dates back to 1924 when Akira Yamada found the Osaka Kinzoku Kogyosho Limited Partnership in Osaka, Japan. It is Daikin’s philosophy and group values that the 90 years old company has strived to reach amongst the top names in the world. At a time, where every invention is integrated with advanced technologies, striving to provide comfort with minimal impact on the environment, is how Daikin functions. It has made its mark globally, with over 90 worldwide production bases. Daikin has always propelled environmental-friendly practices, with every step of its management. From incorporating R-32 refrigerant in residential use air conditioners to inventing air purifying technologies, Daikin’s endeavour has always been to maintain harmony between nature and science. And, we are proud to inform that the eco-friendly practices imbibed in our aesthetically designed products are recently been recognised at the National Energy Conservation Awards 2017. It is an initiative by the Bureau of Energy Efficiency, Government of India, Ministry of Power, to acknowledge industries which perform exceptionally well and achieve efficient utilisation and conservation of energy levels, and we are honoured to receive the Most Energy Efficient Appliance (Fixed & Variable speed Air-Conditioner) Award for the JTKM50 series. Daikin’s JTKM series is equipped with advanced

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technologies and is designed to cater the Indian market. Here are some features which ensure that this series of air conditioners perform efficiently, as well as, the reason behind winning the most energy efficient air conditioners award. Intelligent Eye: It’s an inbuilt infrared sensor that detects the movement of the occupants for providing better airflow and optimum comfort by stabilizing the temperature automatically. Coanda Airflow Technology: It’s a state-of-the-art feature that provides draftless, pleasant air conditioning in every corner of the room. It enables the consumer to enjoy even and pleasant air flow throughout the room. Indoor Quiet Operation: As the name suggests, this feature enables the air conditioning unit to function quietly. Therefore, offering absolute silence so that you can work efficiently. Power Chill Operation: This technology is an impeccable addition to Daikin’s award series, perfect for the Indian weather. This feature enables the unit to quickly maximize the cooling effect in any operation mode. It is the best used for immediate respite from escalating temperatures during the summer months. Streamer Discharge Technology: Daikin’s JTKM series is also equipped with advanced streamer discharge technology, which makes the air conditioning unit work as an air purifier, as well. 

IIR Seeks Award Nominations he International Institute of Refrigeration (IIR) is seeking nominations for its quadrennial scientific prizes, which includes the €8,000 Gustav Lorentzen Medal. The 25th IIR International Congress of Refrigeration (ICR) will take place in Montreal, Canada from August 24-30, 2019 under the theme of ‘Refrigeration for Human Health and Future Prosperity’. The call for nominations for the ICR 2019 Scientific Prizes has now been launched. The series of prestigious academic and scientific awards recognise those who have made outstanding contributions to the field of refrigeration or have completed noteworthy research. In 2019, these awards will comprise: The Gustav Lorentzen Medal is awarded to a person with outstanding and original achievements in academic or industrial research, innovation or development, in all fields of refrigeration.

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Nominations are also sought for the Institute’s Science & Technology Medal and Young Researchers Awards. The Science & Technology Medal is awarded for outstanding achievements over an extended period of time in science and/ or technology in one of the fields of competence of the IIR. Along with a medal and certificate, it carries a prize of €1,600. Eight Young Researchers Awards are also presented for outstanding research work carried out by persons under 35 years of age. The awards comprise Peter Kapitza Award (cryophysics), Carl von Linde Award (cryogenic engineering), Sadi Carnot Award (thermodynamics), James Joule Award (systems and equipment for refrigeration), Alexis Carrel Award: (cryobiology, cryomedicine), Clarence Birdseye Award (food science and engineering), James Harrison Award (refrigerated storage and transport), Willis H Carrier Award (air conditioning and heat pumps). Deadline for nominations is 30 April 2018. 

key benchmarks

Sustainability Report Unveiled at Greenbuild 2017 Co-located with Architecture Boston Expo, Greenbuild 2017 achieves a record-breaking waste diversion rate of 90.5 percent and 25,000 pounds of donations among highlights nforma Exhibitions US and the US Green Building Council (USGBC) announced the release of the 2017 Greenbuild Sustainability Report, highlighting valuable metrics and key benchmarks regarding the impact of energy use and waste management at the 2017 Greenbuild International Conference and Expo, held last November at the Boston Convention and Exhibition Center. Greenbuild co-located its event with the Architecture Boston Expo (ABX). “We’re thrilled to have partnered with ABX, and together we exceeded not only last year’s diversion rate, but ALL previous Greenbuild diversion rates, which is a huge accomplishment for Greenbuild and the events industry,” said Lindsay Roberts, Greenbuild and ABX group director, Informa Exhibitions US. “Our hope is that our lessons learned and achievements can be infused across the events industry. Greenbuild is about sustainability in the built environment, but the way the show is produced leads to these sustainability victories highlighted in this report. We cannot thank enough our dedicated partners and vendors for helping us to cross these milestones.” The comprehensive report details the sustainability program implemented for the 2017 event, through a review of all objectives, goals and best practices. Case studies provide detailed overviews of sustainability strategies and initiatives including waste diversion, attendee and stakeholder engagement, sourcing and donation of materials, performance tracking improvements, and community engagement. Each year, Greenbuild looks to raise the bar on sustainability efforts. This is only possible through the support of incredible partners and vendors as well as our Greenbuild Host Committee,” said Kate Hurst, Senior Vice President of Conference & events, USGBC. “Through our pilot of the TRUE Zero Waste rating system, we elevated our tracking processes and focused on drafting narratives that truly capture our waste reduction efforts. The report shares the progress of seven sustainability objectives at Greenbuild, including the following highlights: • Waste Management: Informa Exhibitions, USGBC, the Boston Convention and Exhibition Center, Freeman, and local vendors worked together to optimize waste management strategies resulting in an overall 90.5 percent diversion rate. This is the highest in the event’s history. It’s also a 44 percent increase over the convention center’s baseline diversion rate. • Stakeholder Engagement: Greenbuild is unique in that sustainability practices permeate the entire event; it’s produced in a genuinely sustainable manner. In 2017, attendees of both

I

Greenbuild and the co-located Architecture Boston Expo were asked to take sustainability pledges. Attendees could commit to taking specific actions, from bringing a reusable water bottle to selecting local or organic food while onsite in Boston. At the event, these pledges were visualized via an interactive Sustainability Hub culminating in 14,500 pledges on-site. • Sustainable Sourcing: Carpet on the expo hall floor was cut in such a way that it could later be re-used by the general services contractor, Freeman. Additionally, exhibitors from Greenbuild and ABX donated more than 25,000 pounds of materials including cement blocks, flooring, carpet, floor tiles and wood, ensuring that it would have a second life. • Performance Tracking: USGBC and Informa were thrilled to have Greenbuild/ABX 2017 participate as the first ever pilot project for the TRUE (Total Resource Use and Efficiency) Zero Waste event certification and achieve a Platinum level certification. The TRUE rating system enables facilities to define, pursue and achieve their zero waste goals. It helps facilities to quantify their performance and find additional ways to improve their progress toward zero waste. • Greenhouse Gas Emissions: One of the largest contributors to greenhouse gas emissions worldwide is landfill and food waste. Working with vendors, Greenbuild and ABX were able to donate more than 1,500 pounds of food and beverages to the Boston Rescue Mission, a local non-profit. • Community Impact: The 2017 Greenbuild Legacy Project chose to support The Green Building Tech Program at Madison Park Technical Vocational High School. The program created early awareness of green building technologies in the trades of facilities management, electrical, plumbing and carpentry. The program exposed the next generation of building operators and trade workers to a wide range of “green collar” jobs. • Hospitality Industry: An updated onsite hotel audit program reflected the wording found in the hotel sustainability contract clauses. Audit items were placed online for our hotel partners to update over the course of the year as they made improvements in the lead-up to the event. The hotels could also sustain these changes after the event was completed. Greenbuild, owned and operated by Informa and presented by USGBC, is the world’s largest conference and expo dedicated to green building.  Cooling India | April 2018| 19

market watch

Cold Chain Market worth USD 293.27 bn by 2023 The growth of cold chain market can be attributed to the growth of international trade of perishable foods, technological advancements in refrigerated storage & transport, government support for the infrastructural development of the cold chain industry…

he global cold chain market is estimated to account for USD 203.14 billion in 2018 and is projected to reach USD 293.27 billion by 2023, at a CAGR of 7.6%. The global cold chain market is expanding with considerable growth potential for over the next five years. The growth of this market can be attributed to the growth of international trade of perishable foods, technological advancements in refrigerated storage & transport, government support for the infrastructural development of the cold chain industry and increase in consumer demand for perishable foods. Also, expansion of food retail chains by multinationals will enhance international trade and impact the growth of the cold chain market.

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Asia Pacific Largest Market The two main types of cold chain infrastructure are refrigerated transport and refrigerated storage. The refrigerated storage market is estimated to be dominated by the Asia Pacific region. Refrigerated storage capacities are growing in the Asia Pacific due to the increased need for reducing wastage of perishable foods. In North America and Europe, the refrigerated transport industry is booming, mainly due to the advancement of technology in refrigerated trucks, vans, trailers, and maritime reefer containers.


Dairy & Frozen Desserts Dairy & frozen desserts are estimated to account for the largest market share in the frozen cold chain market in 2018, due to their need for constant temperature control (being temperaturesensitive products), dust, and exposure to sunlight. Dairy & frozen desserts are witnessing high demand due to economic growth and rapid urbanization, along with sophisticated marketing channels. Government guidelines in China state that milk is a major source of calcium and protein, and recommend regular milk consumption, which has led to milk and dairy products being incorporated into the daily diet of consumers. Frozen products: The most widely consumed type of products preferred in cold chain application. The frozen products segment accounted for the largest share in the cold chain market, in terms of value in 2017. A wide variety of products such as icecream, meat, and seafood are stored at freezing temperatures that range between -18 °C to -24 °C (-0.4 °F to -11.2 °F). Freezing preserves the taste, texture, and nutritional value of foods better than other preservation methods. Cold chain for frozen foods provides uninterrupted handling of the product within a low-temperature environment during the steps of the value chain, which include harvest, collection, packing, processing, storage, transport, and marketing until it reaches the final consumer. 

award

Emerson Innovation Gets ACREX Award of Excellence 2018 manufactured, delivery and service will be quick and easy.” A jury selected the winners after evaluating the product on its features, product data, energy rating testimonial and comparative analysis. Copeland Scroll based heat pumps from Emerson are an innovative offering for residential and commercial applications. The salient features of this solution include a Copeland Scroll™ ‘ZW’ water heating compressor, intelligent system controller for unit monitoring, adjustable water temperature, precise temperature control and full electrical protection – all in a compact package designed for energy efficient water heating. The full range of 300 – 1000 ltr./ hr. units can meet hot water requirement of hotels, hospitals, restaurants, offices, spas, residences, hostels and more. 

merson’s Sanitary Water Heat Pump won the ACREX Award of Excellence in the ‘Technology Developed in India’ category. This is the fourth consecutive time that Emerson won the prestigious and industry recognized ACREX Award. It not only reaffirms Emerson’s commitment in bringing innovative solutions for its customers, it also complements the government’s ‘Make in India’ initiative to boost the country as a global manufacturing hub. Speaking on the occasion, Shirish Adi, Vice President and Managing Director, India for Emerson Commercial & Residential Solutions said, “We clearly have a winner in our hands. The award demonstrates that heat pumps are economically and environmentally viable and water heating solutions are now cost effective for varied applications.” Adi went on to add, “Being locally

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positive impact

Health, Comfort, Efficiency

Three Dimensions of Building Performance Buildings can also be responsible for major health challenges that we are facing today, including everything from obesity to asthma. Alternatively, buildings can also positively promote human health, particularly, with focusing on the indoor air quality, active design strategies, natural lighting and healthy material selection...

uilding performance has become an imperative element in design and operations of buildings of recent times. Often associated with energy efficiency, building performance actually has a great more deal with other vital aspects of human life. It was good advice in the early struggle for better buildings but today the demands are even more challenging: besides not wasting energy, buildings mustn’t suffocate their

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inhabitants nor dull them into a state of laziness. A building can have both positive and negative effects on performance. Negative effects are associated with discomforts, distractions or health risks that interfere with peoples’ ability to do their work whereas positive impacts are associated with enhancing work performance, psycho-social well being, and health to enhance overall performance.

Buildings can also be responsible for major health challenges that we are facing today, including everything from obesity to asthma. Alternatively, buildings can also positively promote human health, particularly with focusing on the indoor air quality, active design strategies, natural lighting and healthy material selection. Apparently, building performance has to be dealt in three-dimensions i.e. Health, Comfort and Efficiency.

positive impact Implications of Energy Efficiency on Comfort & Health

Implications of Visual Comfort on Health Performance enhancement is more likely to come from a different set of building features and attributes that affect performance. For instance, a direct effect would be glare on the computer screen

Source: www.worldgbc.org

Buildings consume over 40% of world’s total energy and thereby, CO2 emissions. With alarming global warming concerns and ever increasing energy costs, energy efficiency has received first priority in the discussion of building performance. The world is now sensitized to a great extent and thus, striving to achieve higher & higher energy efficiency in the buildings. In the quest of saving energy, however, one should not forget that the primary reason of a building’s existence is to be used by humans. Achieving energy efficiency at the cost of human comfort and health must certainly not be the goal. For instance, an airtight building made for higher energy efficiency - if not provided with sufficient ventilation - leads to a common problem of building up of carbon dioxide and various pollutants. This leads to “sick building syndrome,” the term introduced in 1980s to describe the increasingly common maladies caused by improperly designed and ventilated buildings. On the other hand, excess ventilation for comfort and health shall lead to higher energy consumption and an air-leaked building may even let outdoor pollutants to infiltrate in the building causing health issues for its occupants.

Figure 1: Positive impact of daylighting on mood

that interferes with the ability to see written words or numbers whereas an indirect effect operates through an intermediate mechanism such as mood or motivation. A common example is the positive impact of daylighting on mood. The assumption is that daylight makes us feel good and therefore, should make us more motivated to work. Lack of sunlight may upset sleep-wake cycle and other circadian rhythms that may lead to Seasonal Affective Disorder (SAD), a type of depression that affects a person during the same season each year. As per a field study of office workers, it is found that workers who had window views of nature felt less frustrated and more patient, and reported more overall life satisfaction and better health than workers who did not have visual access to the outdoors or whose view consisted of built elements only. The positive effects of nature may also extend to the immune system, thereby, directly affecting human physical health. Lighting that produces glare leads to

visual discomfort that is more likely to be associated with headaches and eye problems. Thereby, one of the perennial challenges in daylighting is providing an even distribution of diffused daylight across the building section. Glare due to direct solar penetration and due to the lack of luminous uniformity across the space distorts the perception of good indoor daylighting. Thereby, façade designs of the buildings have to be carefully done in order to achieve glare-free daylight for visual comfort whilst still taking care of energy efficiency. Various computer simulations like daylight distribution studies; visual comfort and glare analysis are being conducted now-a-days that help optimizing the buildings’ design to enhance performance and achieve visual comfort at the same time. These simulations evaluate building designs to identify potential concerns related to daylight distribution and provide solutions to ensure appropriate illumination of spaces. It also assists designers in analysing potential areas receiving disturbing glare

Figure 2: Various computer simulations like daylight distribution studies


positive impact optimum combination of proper buildings materials, effective ventilation systems design and indoor pollutant control mechanism. Some broad guidelines for better IAQ are briefly described below:

1. Measure during Design a. Selection & use of non-toxic materials b. Effective ventilation systems c. Adequate fresh air supply d. Appropriate pressures e. Efficient air-filtration

2. Measures during Construction a. Store materials in dry places b. Keep equipment packed until used c. Cover duct openings after installation d. Isolate the finished areas e. Effective housekeeping f. Dust absorbing materials at last

3. Measures during Operations a. b. c. d.

Figure 3: Optimizing the façade design to achieve glare free daylight in occupied spaces

and providing solutions to control direct sunlight at visual task areas. Shown in Figure 3 is a project example where our sustainability team was specifically engaged to optimize the façade design with an aim to achieve glare free daylight in occupied spaces.

Impact of Indoor Environmental Quality IEQ encompasses more than air quality, including thermal comfort, visual


comfort and acoustical quality. Due to the fact that, as humans, we spend almost 90% of our time indoors, it’s only natural that quality of the indoor environment can have big impacts on our health and efficiency. The World Health Organization (WHO) has estimated that 4.3 million people in 2012 lost their lives due to indoor air pollution. Estimates from the WHO and others suggest that between 30 and 150 times more people are killed due to indoor air pollution than global warming. Even though the factors that affect quality of indoor environment are numerous, the good news is that most indoor environmental problems can be prevented or corrected. Having said that, achieving better IAQ in buildings requires proper application of science & technology. It calls for an

Refrain from blocking air vents Smoke in designated areas only Clean up spills immediately Report any water leaks to management e. Dispose off all garbage promptly Above strategies can be a good start, however, there are several other more elaborated strategies applicable to different type of buildings and/or applications.

Summary Building performance is a philosophy as well as a science, which cannot be perceived with a single element in isolation. When a building performs to its design, the engineering and architecture of the building work together in harmony to deliver the optimum ‘Building Performance’ for the human inhabitants. Therefore, an Integrated Design Approach must be applied in a building design with the blend of advanced computer simulation techniques to validate and achieve a balance in all ‘3-dimensions of Building Performance’. 

Ashish K Jain

IMPM, FAAPM, AIID, LEED AP, IGBC AP, GRIHA CP Partner - AEON Integrated Building Design Consultant LLP

positive impact


positive impact

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recognition

Two BITZER Compressors Get ACREX Awards of Excellence

The BITZER team with the two award-winning compressors

verwhelming success for BITZER: the world’s biggest independent manufacturer of compressors has won not one but two ACREX Awards of Excellence. At the ACREX trade show in Bengaluru, the jury awarded the prize for the category Green Products to the OS.A95 screw compressors for the natural refrigerant ammonia and to the ECOLINE reciprocating compressors with IQ module in the Innovation category. At the ACREX India trade show from 22 to 24 February, BITZER presented an expert audience with the company’s newest products and future-oriented innovations, and prompted a pleasantly high resonance with trade show visitors. At the trade show, the ACREX Awards of Excellence are granted annually. ‘We were able to convince the jury with two products and are proud that the independent panel has awarded this important prize to our innovations”, says Harvinder Bhatia, Managing Director at BITZER India. The BITZER OS.A95 screw compressor won the prize in the category Green Products. With this energy-efficient compressor

O

series, BITZER offers a climate-friendly and powerful solution for ammonia applications. The natural refrigerant has no globalwarming potential and does not damage the ozone layer. Their cooling capacity and automatic Vi adjustment make OS.A95 screw compressors suitable for a whole host of applications. In combination with automatic Vi adjustment, the series’ extensive application-limits diagram enables efficient use of the series in air-conditioning, medium and low temperature systems as well as in heat pump applications. The optimised rotor profiles, the high internal tightness and the large flow cross sections in the compressor also contribute to efficient operation. Typical applications of the OS.A95 screw compressors include mediumand low-temperature refrigerated distribution warehouses, shock freezers and process liquid chillers. Among the winners of the ACREX Awards of Excellence are also the ECOLINE reciprocating compressors with IQ module, as runner-up in the Innovation category. ECOLINE reciprocating compressors offer maximum energy efficiency in full- and partload and are designed for a very extensive range of applications in supermarkets and beyond. One of the series’ benefits: it offers maximum freedom in the selection of the refrigerant. Whether new climate-friendly refrigerants such as R1234yf, R1234ze(E), lowGWP blends or natural refrigerants, users will always find a suitable, eco-friendly solution in ECOLINE. Thanks to the intelligent IQ module, ECOLINE reciprocating compressors represent a milestone in terms of energy efficiency. In combination with the VARISTEP mechanical capacity control, users are able to infinitely adjust compressor capacity between 10 and 100 per cent – a true alternative to frequency inverters. The IQ module monitors the system independently and sends out a warning if the specified applications limits are exceeded. 


efficiency

Towards Efficient Compressors Compressor is an integral part of HVACR equipment. When these equipment are becoming indispensable with present civilization, role of compressor with its improved efficiency becomes more important in the era looking towards sustainable development through energy conservation...

Picture Credit: Emerson Climate Technologies (India) Pvt. Ltd.

Compressor: An Integral Part


Heating, ventilation, and air conditioning (HVAC) is the technology of indoor and vehicular environmental comfort. Its goal is to provide thermal comfort and acceptable indoor air quality. The compressors are one of the most important parts of the refrigeration cycle. The compressor compresses the refrigerant, which flows to the condenser, where it gets cooled. It then moves to the expansion valve, and the evaporator and it is finally sucked by the compressor again. For the proper functioning of the refrigeration cycle, the refrigerant must be compressed to the pressure corresponding to the saturation temperature higher than the temperature of the naturally available air or water. It is the crucial function that is performed by the compressor. Compression of the refrigerant to the suitable pressure ensures its proper condensation and circulation throughout the cycle. The capacity of the refrigeration or air conditioning depends entirely on the capacity of the compressor. There are various types of compressors used in the refrigeration and air conditioning machines, these are: reciprocating, rotary, screw, centrifugal and scroll. Thus, compressor in its various types, capacities and shapes is an integral part of heating, ventilation, air-conditioning and refrigeration equipment. When these equipment are becoming indispensable with present

efficiency civilization, role of compressor with its improved efficiency becomes more important in the era looking towards sustainable development through energy conservation.

Compressor Efficiency

Picture Credit: hvacbeginners.com

In order to evaluate the energetic quality of a compressor (as with all energy machines) efficiency is calculated. With piston compressors also a volumetric efficiency is being used, which is defined as the useable part of the piston displacement for gas delivery. The mechanical efficiency varies with compressor size and type, but 95% is a useful planning number. When calculating the compressor head and discharge temperature the efficiency used will be isentropic or polytropic (isentropic efficiency is sometimes called adiabatic efficiency). The isothermal efficiency compares the achieved pumping work with the work input. The pumping work is the product of mass flow and the mass specific work required at ideal isothermal conditions. The mass flow of the compressor can be obtained by measuring the volume flow and the inlet conditions. By also measuring the delivery pressure the isothermal work can be calculated. The power required is the power input at the clutch, which is obtained by measuring the torque and the revolutions per minute. Part of the power input is used up as the mechanical power loss (friction in the drive mechanism and the sealing elements, also the work input of auxiliary aggregates such as lubricators, cooling pump). The remaining internal work, which is transmitted by the piston onto the gas, is larger than the pumping work by the amount of the internal power losses. After the experimental evaluation of the cylinder pressure, which varies with time and crank angle, or by simulating the thermodynamic processes in a calculation which comes near to the real conditions, the internal work can be derived by the areas of the P, V- diagrams of all working chambers. With smaller pressure ratios the throttling losses become more important. With larger pressure ratios the additional work

Figure 1: Role of compressor

due to deviations from the isothermal compression rises. The maximum achievable efficiency rises with the number of stages, as the approximation to the isothermal process increases. In the ideal case the complete piston displacement at the end of the suction stroke is filled with gas at inlet condition. It would contain the complete displacement mass. The actual delivered mass after a compression cycle is always smaller then the ideal piston displacement mass. The ratio of the actual delivered to the ideal mass per compression cycle or the respective mass flows is called the volumetric efficiency. However, this parameter does not have a direct indication of the energetic efficiency of the compressor. Studies have concluded that industrial plants waste roughly 30 percent of generated compressed air, which could equate to $9,600 for a typical scfm installation, or as much as $32,100 for 1,500 CFM. Estimates also indicate that poorly designed compressed air systems result in wasted utility payments of up to

$3.2 billion. Energy efficient air compressors will not only save money but will also help control pollution. A walkthrough assessment can help identify conservation opportunities in compressed air system. Large-scale air emissions are released when electricity is produced. Reducing the electricity needed for compressed air systems can help significantly improve air quality. Many industrial compressors use oil for lubrication, creating an oil and water mixture called condensate, which contains hydrocarbons and other harmful contaminants that require proper disposal in accordance with government guidelines. Oil water separators, used in condensate management systems, can help efficiently remove waste.

Optimizing a Compressor Single-stage reciprocating compressors have one or more cylinders connected in parallel to compress air from atmospheric pressure to the final discharge pressure in one step. Most single-stage Cooling India | April 2018| 29

efficiency Typical specific power at single-stage) to 500 hp. Common sizes for higher initial price, more expensive installation and higher maintenance costs than other types of compressors.

Figure 2: Theoretical Compressor Efficiencies

compressors are designed for a maximum discharge pressure of 100 psig. Multistage reciprocating compressors, on the other hand, have two or more cylinders connected in series. Each stage adds some degree of compression. For example, in a two-stage unit, air is compressed from atmospheric pressure to an intermediate pressure in the first stage, cooled by an intercooler and raised to the discharge pressure in the second cylinder. Multi-stage reciprocating compressors are more efficient, run cooler and have longer life than single-stage compressors, all because the intercooler(s) remove the heat of compression. While not typical for plant air, some special-application, twostage compressors can deliver 250 psig or more. Single-acting reciprocating compressors are commonly air-cooled, have one or two stages and available to 150 hp. However, in most industrial applications, the maximum size is generally 30 hp. A measure of operating efficiency is called specific power and is the kW input to produce 100 cfm, or kW/100 cfm. For a single-stage, single-acting compressor, the specific power is approximately 24 kW/100 cfm at 100 psig. Typical specific power for a two-stage, single-acting compressor at 100 psig is 19 kW/100 cfm to 21 kW/100 cfm. Double-acting compressors are generally water-cooled and range in size from 25 hp (two-stage industrial applications range between 75 hp and 250 hp. A two-stage double-acting 30 | Cooling India | April 2018

reciprocating 100 psig is approximately 15 kW/100 cfm to 16 kW/100 cfm. Doubleacting compressors have a compressor is the most energy-efficient air compressor.

The lubricated rotary-screw air compressor is the most widely used design for industrial applications. It is characterized by low vibration, a simple installation with minimal maintenance in broad ranges of capacity and pressure. A rotary-screw air end consists of two close-clearance helical rotors turning in synchronous mesh. The male rotor has four helical lobes and the female rotor has five or six mating grooves. In a lubricated rotary screw compressor, the male rotor drives the female rotor. Ambient air is drawn through a suction port into a space

Picture Credit: gasprocessingnews.com

Picture Credit: www.emersonclimate.com

Rotary Compressors

Figure 3: Optimize compressor parameters

efficiency between the spinning rotors, which then force the air into the decreasing inter-lobe cavity until it reaches the discharge port at the opposite end of the rotor. Oil injected into the rotor housing lubricates the moving parts, removes heat and seals the clearances to prevent back slippage of the compressed air. The air/lubricant mixture discharges into the lubricant reservoir, which also serves as a separator that relies on directional and velocity changes. A coalescing-type filter reduces the final lubricant-to-air concentration to 3 ppm to 5 ppm. Operating at too low a system pressure (65 psig to 75 psig) increases the velocity across the separator, which leads to greater lubricant carryover. To prevent carryover at startup and when system pressure is too low, a minimumpressure device is used to maintain internal compressor pressure above the manufacturer’s minimum. The lubricant separated from the air stream circulates through a cooler and filter before being injected back into the air end. The

temperature of the lubricant at the injection port needs to be high enough to prevent condensation from forming in the lubricant. Air-cooled units use a thermostatic valve to maintain an injection temperature of 150°F to 170°F. Water-cooled packages use a water-flow-regulating valve or thermostatic valve, or both. To remove condensate, rotary-screw packages use an after cooler to reduce the discharge air temperature and a moisture separator with an automatic drain. Most industrial applications use air-cooled heat exchangers for the lubricant and compressed air. Water-cooled models use shell-and-tube exchangers. Single-stage lubricated rotary-screw compressors are available in sizes from 5 hp to 600 hp and produce between 35 psig and 210 psig. Typical 100-psig specific power at full load is approximately 18 kW/100 cfm to 19 kW/100 cfm. Variable-displacement or variable-speed capacity control can improve part-load efficiency. Two-stage compressors are

available for operation upto 500 psig. They generally achieve better energy efficiency when used as base-load compressors. At 100 psig, specific power is approximately 16 kW/100 cfm to 18 kW/100 cfm. Variable-speed control can also make them suitable as trim compressors. Nonlubricated rotary-screw air ends are similar to the lubricated variety, except for the lack of lubricant injection. Two types are available - dry and water-injected. In the dry type, the male rotor doesn’t drive the female rotor. Instead, timing gears, which are separated from the compression chamber by lubricant seals and air seals, maintain proper rotor clearances. The operating temperatures are around 350°F to 400°F because there’s no fluid injection to help remove the heat of compression. Single-stage models can reach 50 psig. Most manufacturers use a two-stage design with an interstage cooler to produce pressures of 100 psig to 150 psig. Typical specific power at 100 psig is approximately 18 kW/100 cfm to 22 kW/100 cfm. The


Picture Credit: www.fluidairedynamics.com

efficiency

Figure 4

water-injected, non-lubricated rotaryscrew compressor can produce 100 psig, and more in a single stage because the water injected into the compression chamber seals clearances and removes the heat of compression. The water is removed by conventional means, cooled and recirculated. Automatic controls maintain the water level and quality.

Dynamic Compressors A dynamic compressor uses highspeed impellers to impart velocity to the air. A centrifugal compressor is similar to a centrifugal pump, with ambient air entering at the center of a high-speed impeller that accelerates the air radially. This velocity head is translated to pressure head at the discharge volutes or diffusers. The number of stages and impeller blade configuration determines the operating pressure and flow rate. Most industrial centrifugal air compressors use a multi-stage design. Backward-leaning impeller blades can achieve higher discharge pressures, but somewhat lower flow. Radial impeller blades might achieve greater flow, but at lower pressures. Your air demand and pressure variation limitations determine the best configuration. Compressor manufacturers have controls to avoid the phenomenon of surge, where air flow reverses inside the compressor. As the compressor discharge pressure increases, flow decreases. Eventually, the discharge pressure can’t overcome the system pressure and the air flow reverses, going from discharge to inlet. Most capacity 32 | Cooling India | April 2018

controls automatically avoid this condition at low demand. Typically, centrifugal compressor sizes start at approximately 150 hp and the specific power at 100 psig is approximately 15 kW/100 cfm to 20 kW/100 cfm. The sliding-vane rotary compressor uses a rotor with metallic or non-metallic vanes that slide in and out of the rotor in an offset housing. As the rotor spins, the vanes are forced outward against the cylinder walls. During part of the revolution, the contained volume between vanes decreases, and pressure rises as it nears the discharge port. The rotary-scroll compressor is a relatively new design in sizes from fractional to 7.5 hp. Because of its small footprint, multiple compressors and drives can be mounted on a common base to provide higher capacities. One of two identical intermeshing spirals or scrolls is stationary and the other oscillates in relation to the stationary scroll. The spirals are mounted with 180° phase displacement to form air pockets with variable volumes. As the moving scroll orbits within the fixed scroll, the air pockets diminish in size as they scroll spirally toward the center. Most scroll manufacturers limit maximum discharge pressure to 115 psig.

Choosing Efficient Compressor There are many uses of compressed air. In fact, 70 percent of all manufacturers use a compressed air system, for use with machine tools, material handling, as well as spray painting and separation

equipment. One reason for that popularity is the safety and convenience of using air as a resource, as opposed to other energy sources such as electricity. An air compressor can also function at high temperatures and in locations where explosions and fire hazards restrict other forms of energy. Air can be generated on site, so there’s more control over usage and air quality. Also, air compressors can run tools and equipment that generate more power than normal tools. When using pneumatic tools, an air compressor becomes a vital part of operation. The most popular compressors are positive displacement compressors, which work by filling a chamber with air and then reducing volume. Positive displacement compressors include reciprocating, rotary screw and rotary vane compressors. Although reciprocating compressors are the most widely available on the market, rotary compressors are most useful in industrial environments. Air compressors are a substantial investment for business owners, so the process of purchasing one requires consideration of many factors. Understanding business needs will help determine what compressor will meet those needs. The following considerations should help to choose the right air compressor system: • Choose the right size • Select an air compressor that provides enough airflow • As per work environment • Suitable size of the compressor tank • Determine the horsepower needed • Consideration to control systems • Using the right protection The largest cause of energy waste results from unused, or leaked, compressed air. Heat loss is also a large component of wasted energy in the air compression process. Just as increasing pressure can cause production inefficiencies like artificial demand and leaks, so will lowering side pressure without doing anything else. Understanding the capabilities of the system will help verify whether air compressors are too big for end users, since the end use requires a

efficiency small percentage of the pressure created. If repairing leaks and adjusting controls prove insufficient, it may be time to upgrade to more energy-efficient, costeffective equipment. Keep in mind that energy savings from a more energyefficient air compressor should help recover any increase in costs. So it makes sense to replace old technology with new, energy-efficient parts. Implementing preventive maintenance will ensure compressors are operating properly and efficiently, preventing the high cost of downtime and lost production. When not in use, they should be shut down. If weekends or evenings still require air, consider investing in a smaller-capacity air compressor for such times. With energy costs doubling in the last five years, it couldn’t be more crucial to make compressor more energy efficient. The main causes of inefficiencies are the following: • Leaks • Pressure drops • Over pressurization • Poor management of the compressor • Use Flow Controllers • Recover Wasted Heat • Change Filters

Steps to Improve Compressor Energy Efficiency There are three steps that every industrial compressor owner should consider when optimizing energy spending. Pressured air from compressors is widely used but it is energy intensive. Compressors are operated in very different conditions and annual running hours vary a lot. Studies demonstrate that there is space for energy efficiency improvements. Studies indicate that the improvement potential is on average 15%. However, the range is wide and in many cases energy efficiency specialists have easily made 30% in savings. Three elements are needed to achieve major savings. The first is the awareness and we should carry out energy appraisals of compressor-inuse at regular intervals. The second element is control and replacing simple on-and-off control with a sophisticated

variable speed drive (VSD) based control system keeps the pressure in air pipes stable and supplies the required air flow. It also reduces compressor motor starts, service requirements and extends the motor’s life time. It even supports leakage detection. As of today only about 5% of compressors are controlled by VSD. The third element is an energy efficient motor to drive the compressor shaft. Reluctance motors, which are a brand new motor technology, reach better efficiencies.

Future of Energy Efficient Compressor Technology The evolution of air compressor technology is a lot like the automobile industry. As new technologies that reduce fuel consumption without sacrificing performance are perfected, more drivers are demanding the new technologies in order to save money and contribute to a healthier planet. The air compressor industry is also revolutionizing technology and offering a more sustainable option for compressed air users. With rising energy costs and growing demands for environmentally sustainable processes, it is more important than ever to implement technologies that reduce energy consumption. By investing in new technology, compressed air users can reduce energy consumption and operation and maintenance costs while increasing performance and contributing to a healthier, more sustainable planet. The future of air compressor technology lies in the variable speed drive (VSD) compressor. Before the introduction of highly energy-efficient VSD technology, a traditional load/unload compressor of the same type suited some manufacturing processes better than a VSD compressor. Now, with the introduction of VSD+ compressors that can reduce energy consumption by up to 50%, the traditional load/unload type of compressor can be replaced with a VSD compressor for the majority of processes. Additionally, the return on investment for switching to a VSD compressor is higher and the payback time is shorter than ever before. In the last few years, the compressor industry has seen the release of several

innovative, patented air compressor technologies that significantly reduce energy consumption. These recent advancements derive from improvements throughout the compressor design and contribute to dramatic increases in energy efficiency. One of the most efficient compressor designs prior to 2013 was the variable speed drive (VSD) compressor, which provided average energy savings of 35 percent compared to a traditional load/ unload compressor of the same type. After years of research and development, the energy efficiency has been increased by up to 50 percent by revolutionizing the design of the VSD compressor and launching the VSD+ product line. These compressors use a vertically-aligned design where motor and drive train share a single drive shaft that significantly reduces the footprint, allowing the compressor to be installed closer to the point of use. The introduction of a single, closed oil-circuit that cools the motor while lubricating the element and bearings contributes to a more reliable compressor. A fan design that mimics the wings of an owl contributes to a highly efficient cooling mechanism while simultaneously decreasing noise levels. All of these little changes make a big impact when combined in one air compressor. The simplified design of these compressors, coupled with advancements in technology, provide energy savings throughout the entire lifetime of the compressor. With rising energy costs and growing demands for environmentally sustainable processes, it has never been more important to implement technologies that reduce energy consumption. By investing in new technology, compressed air users can reduce energy consumption and operation and maintenance costs while increasing performance and contributing to a healthier, more sustainable planet. 

Dr S S Verma Department of Physics, S.L.I.E.T., Longowal, Distt.: Sangrur (Punjab)


interview

“We just don’t provide instruments but we explore, develop solutions” With its head office located in Pune, it caters to different industrial sectors across India ranging from steel & cement to food & pharma. Kalidas Bhangare, Managing Director, Testo India Pvt Ltd sheds light on the major landmarks of the company, products and services, Refrigeration Measuring Technology and much more during an interaction with Cooling India…

What are the major landmarks in the journey of Testo India? Established in 2006, Testo India Pvt Ltd is a 100% subsidiary of Testo SE & Co KGaA which is a world leader in design, development and manufacturing of electronic portable test and measuring instruments and is backed by 60 years of measurement engineering experience. With new products and innovations getting added to the basket year after year, extending our reach throughout the nation, increasing our support and services in every aspect Testo India gained incredible acknowledgement from the Indian market as well. We have shown phenomenal growth over the last 11 years. 34 | Cooling India | April 2018

With our Head office in Pune, & a PAN India sales and channel partner network, Testo India now enjoys a prominent position in Test & Measurement industry. We have an established state-of-theart service & calibration lab located at Pune that is accredited by Germany. We have been therefore providing not just sales but also after-sales service to industries ranging from Food & Pharma to Cement & Steel, HVACR among others.

How is Testing and Measurement instruments market evolved over the years? The advancements that we are now witnessing are the after

What are the trends in Refrigeration Measuring Technology? Have you witnessed major transformations in this technology over the years? The current trends in the refrigeration technology are highly digitized and user friendly, but we have relied on age old analog measurement system for a very long time. With time, requirements have changed as many different parameters, such as pressures and temperatures, along with the superheating and sub-cooling of the system, have to be checked now. An analog manifold is not really much help with this, as it can only determine high and low pressure. For every other task, you need additional instruments and accordingly more expenditure, apart from the laborious handling and the frequent inaccuracies of measurement. Also, modern refrigeration and air conditioning systems are becoming more and more complex requiring better and better

Testo include: The digital manifold kits testo 550 and testo 557 – including filling hoses. These instruments are perfect for the complete servicing of heat pumps, air conditioning and refrigeration systems. The digital manifold kits testo 550 and testo 557 stand out, thanks to two clamp probes, a vacuum probe (testo 557 only), the robust case, and above all the respective filling hose set. Linked by Bluetooth to the testo refrigeration app, the manifolds now make work even easier. System parameters such as sub-cooling and superheating can be monitored from upto 20 meters via a smartphone or tablet. Sending a report by e-mail and automatic, free updates with new refrigerants are also among the strengths of the little digital helper for iOS and android. The new testo Smart Probes AC & refrigeration test kits are the unique solution for fast testing of heat pumps, air conditioning and refrigeration systems: Two high-pressure measuring instruments Cooling India | April 2018 | 35

interview

effects of performance. New refrigerants are constantly being introduced, digitization of the and old ones taken off the market. New legislation & regulations working system. are changing the requirements regarding energy efficiency and The traditional environmental protection. Due to which the measurement methods and technology used for commissioning and servicing the plants must processes are perform accordingly. Being the world leader in measurement now getting technology, Testo has not only witnessed but in fact has replaced with introduced the biggest technological leap in refrigeration industry smart solutions. with its new smart manifolds and smart refrigeration probes All the time which work through an app on your smartphones/ tablets making c o n s u m i n g , every day refrigeration tasks easier. manually driven How would you differentiate Indian Refrigeration operations can now be governed Measuring Technology from the global standards? with just one click Global market is certainly way different to our Indian market and of the smartphone a big share of credit goes to the climatic difference. Heating, for making the example, forms a major part of the HVAC&R market in Europe due process more to the cold weather conditions prevailing there. In India, heating easy, accurate, needs are almost close to nothing. The demand for VAC & R fast and reliable. efficiency monitoring and management is at its peak during the Human error, summer season. Facility Management too is becoming an tedious calculation & validation processes, manual data recording important market owing to the spurt of huge IT buildings, malls, and storage are old school notion now as they do not satisfy the hospitals etc. The concept of green building too is taking strong footing in the Indian market. modern-day applications. Inclusion of measurement techniques via Bluetooth/wifi, cloud storage and other IoT concepts has taken the measurement industry by storm. The current trends in the refrigeration technology are highly digitized and Where data were once being analyzed by user friendly, but we have relied on age old analog measurement system for a printing out the measurement protocol and laboriously saved on the PC, all measurement very long time. With time, requirements have changed as many different results can now be graphically displayed parameters, such as pressures and temperatures, along with the superheating and immediately dispatched on site by and sub-cooling of the system, have to be checked now. e-mail - whether to the office or to the customer. These smart & intuitive instruments with their wireless operation, What are the Refrigeration Measuring Technology ease of saving & transferring data over networks are more user- products? What is the USP of your products? friendly and cost effective. Some of the smart high precision and efficient solutions from

involvement is assured with our products which ultimately improves accuracy, reduces downtime of facilities and reduces errors, which is almost everything you seek.

What technological innovations would you like to incorporate in your products to make them more energy efficient and sustainable? Do you have R&D hub in India?

interview

Testo smart probes set - refrigeration

(testo 549i) and two clamp thermometers (testo 115i) are available in the new, testo Smart Probes HVAC soft case. The testo Smart Probes AC & refrigeration test kit is supported entirely by the testo Smart Probes App. In addition to 80 refrigerants, intuitive menus are also stored for the automatic calculation of superheating/sub-cooling and evaporation/condensation temperature. Documentation with photos and comments can be carried out completely paper-free by e-mail protocol. In addition to electronic refrigeration manifolds, Testo also has digital vacuum measuring instrument like testo 552 for the evacuation of refrigeration/air conditioning systems and heat

Testo is very much aware of the latest trends and value additions that are on-going in the segment. Be it about the technology or the changes in the environment our focus has always been to share a solution which is not only advanced but is also in-line with the necessary environmental norms and specifications. We are extending our range of HVAC/R tools keeping in mind these changes. The way we made our products smart, incorporated digital approach to measurement techniques, we will continue to innovate and develop something better. We have our manufacturing in Germany and thus the R&D is taken care at the HQ. But in India, we do offer certified calibration according to all valid guidelines. The calibrations take place at Testo’s own accredited high-tech laboratory at our facility in Pune so that the instruments can be calibrated & serviced locally maintaining international standards.

What are the growth drivers of your business?

The most crucial factor that really drives our business is the fact that we just don’t provide instruments to measure mere parameter but we also explore, develop and provide solutions for our industry considering the increasing The most crucial factor that really drives our business is the fact that applications. Another determinant could be the policies of the government and the awareness of the user about we just don’t provide instruments to measure mere parameter but we the importance and advantages of these policies. Testo also explore, develop and provide solutions for our industry India caters its services to a wide range of industries, considering the increasing applications. starting from general industries to food, pharma & HVAC. It is very necessary to have stringent norms & guidelines in these sectors to improve the efficiency pumps. It measures even the smallest absolute pressures and and quality as well. Our products are designed with features that provides highly precise information on the status of the comply with standard norms which are very vital for safety and dehumidification of a system (removal of foreign substances, incl. health purposes. Our after sales service and calibration support oils or foreign gases). also adds to the growth as it encourages the customers to select Another tool that Testo provides and which should be a part of Testo as their partner. every professional’s refrigeration technology equipment is testo 316-3 - electronic leakage detector for refrigerants. It detects even What is your outlook for Refrigeration Measuring the smallest leaks, thanks to its high level of sensitivity. It helps segment? the engineer to trace the leaking spots and thus saves the Let’s summarize: refrigeration system maintenance is becoming expensive gas from leaking which also is a reason for an almost as easy as writing WhatsApp messages, and Testo’s inefficient system. smart measuring technology has played a crucial role in the About USPs, our products are smart, intuitive, user friendly, revamp of Refrigeration measuring segment. App-controlled advanced and precise. Most of them could be governed even via manifolds make additional measuring instruments superfluous, a smart phone or tabs. Data transfer, report storage and sharing streamline your entire work process and save a lot of effort as can be done on site. You can inspect and check the status of any well as loads of valuable time. You can ensure energy conservation; desired set up from anywhere and in case of any ambiguity you record precise measurement values and your day-to-day work even receive alerts via mail and message. Reduced human finally becomes part of your own smart world too. 


interview Cooling India | April 2018 | 37

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innovation

Dual Barrier Coating: Reducing Dust in ACs An advanced technology that protects air conditioners from the ill effects of dirt and dust is the dual barrier coating technology. This technology helps in reducing the attachment of dust and oil mist that coats the inside of the conditioners. The coating material greatly reduces the attachment of dust which is mixed in the air. This lends the units the power to work at full performance…

irt and dust are some of the biggest enemies of air conditioners. They slow down the machines and fail to cool the room. Once the damage is too heavy, there may even be a need for replacement or the concurrent repair costs may prove to be cumbersome. Air conditioning area generally contains different types of dirt. Classified into two groups, hydrophilic dirt refers to dirt such as fiber dust and sand dust and hydrophobic dirt is dirt such as oil and cigarette smoke. At times when the inside components of indoor air conditioners are left dirty, the consequences can be harmful to the unit. There are chances that the air flow volume is reduced, the air conditioner may get mouldy, the outlet air may smell bad or there may be deterioration in the energy efficiency of the air conditioner system. An advanced technology that protects air conditioners from the ill effects of dirt and dust is the dual barrier coating technology. This technology helps in reducing the attachment of dust and oil mist that coats the inside of the conditioners. The coating material greatly reduces the attachment of dust which is mixed in the air. This lends the units the power to work at full performance. The reduction in dirt also means the bad smell and odours godown. With less dirt, the necessity of cleaning the air conditioner also lessens.

D

Another upside of the dual barrier coating technology is its green effects. The technology is environment-friendly and does not cause harm to the ozone. Currently, the air conditioners use the dual bar rier technology in its unit. It offers “Dual Barrier Coating” which works as a two barrier coating with blended fluorine particles that prevent hydrophilic dirt penetration and hydrophilic particles that prevent hydrophobic dirt from getting into air conditioner. This dual coating on the inner surface keeps the air conditioner clean round year. AC units are equipped with a sophisticated, streamlined design and a comprehensive range of features to make stylish, energy efficient air conditioning available for countless small businesses. These also consist of double vanes on the indoor unit that operate independently to distribute airflow evenly throughout the room and the company’s MSZ-LN offers a whisper-quiet operation as low as 19 dB(A). A Plasma Quad Plus filter also uses powerful plasma technology to filter out even microscopic particles, whilst the dual-barrier coating on the heat exchanger, fan and air duct prevents dust and grease accumulation. The company offers Dual Barrier Coating in their current model MSYGN & MSZ-LN and in the upcoming model MSY-JP. 

Yozo Ito Director and BU Head, Air conditioners, Mitsubishi Electric India


fundamentals

Compressor in Refrigeration System A compressor is generally a power consuming device in which we input some amount mechanical work as minimum as possible. It draws the refrigerant in as a gas from the evaporator, compresses it and delivers it at higher pressure to the condenser. Thus, the compressor helps in circulating the refrigerant inside the circuit… entering the compressor must be in the gaseous state, as liquids are notoriously incompressible. The compressor starts working when the unit needs to provide cooling and is usually activated via temperature control systems.

Classification of Compressors

efrigeration and air-conditioning is one of the most important sectors in the present world. The vapour compression refrigeration cycle is widely used in domestic and industrial refrigeration systems. The compressor is a very essential component to run the vapour compression refrigeration cycle. A refrigeration compressor is a mechanical device that increases the pressure of a gas (refrigerant vapour) by reducing its volume. It intakes a definite quantity of working fluid (usually a gas or moist air) and deliver it at a higher pressure. A

R


compressor is generally a power consuming device in which we input some amount mechanical work as minimum as possible. It draws the refrigerant in as a gas from the evaporator, compresses it and delivers it at higher pressure to the condenser. Thus, the compressor helps in circulating the refrigerant inside the circuit. It provides volumetric compression, i.e. a progressive reduction in volume, using rotating or reciprocating systems. Compressor power consumption depends on the difference between the two operating pressures. The refrigerant

a) Based on arrangement of compressor motor or external drive: • Open type: In open type compressors, the rotating shaft of the compressor extends through a seal in the crankcase for an external drive. The external drive may be an electrical motor or an engine (e.g. diesel engine). The compressor may be belt driven or gear driven. • Hermetic compressors: In hermetic compressors, the motor and the compressor are enclosed in the same housing to prevent refrigerant leakage. The housing has welded connections for refrigerant inlet and outlet and for power input socket. Hermetic compressors are normally not serviceable. They are not very flexible as it is difficult to vary their speed to control the cooling capacity. • Semi-hermetic compressors: In some (usually larger) hermetic units, the cylinder head is usually removable so that the valves and the piston can be serviced. This

fundamentals type of unit is called a semi-hermetic (or semi-sealed) compressor.

Compressors

Open Type

Hermetic

SemiHermetic

Figure 1: Classification of compressors based on motor drive

b) Based on Working Principle: • Positive Displacement Type: In positive displacement type compressors, compression is achieved by trapping a refrigerant vapour into an enclosed space and then reducing its volume. Since a fixed amount of refrigerant is trapped each time, its pressure rises as its volume is reduced. When the pressure rises to a level that is slightly higher than the condensing pressure, then it is expelled from the enclosed space and a fresh charge of lowpressure refrigerant is drawn in and the cycle continues. Since the flow of refrigerant to the compressor is not steady, the positive displacement type compressor is a pulsating flow device. • Rotodynamic Type: In rotodynamic compressors, the pressure rise of refrigerant is achieved by imparting kinetic energy to a steadily flowing stream of refrigerant by a rotating mechanical element and then converting into pressure as the refrigerant flows through a diverging passage. Unlike positive displacement type, the rotodynamic type compressors are steady flow devices, hence are subjected to less wear and vibration. Depending upon the construction, rotodynamic compressors can be classified as centrifugal and axial flow compressors. Centrifugal Compressor: It is also known as turbocompressors belong to the rotodynamic type of compressors. In these compressors, the required pressure rise takes place due to the continuous conversion of angular momentum imparted to the refrigerant vapour by a high-speed impeller into static pressure. Unlike reciprocating compressors, centrifugal compressors are steady-flow devices. Hence, they are subjected to less vibration and noise. Figure 3 shows the working principle of a centrifugal compressor. As shown in the figure, low-pressure refrigerant enters the compressor through the eye of the impeller. The impeller consists of a number of blades, which form flow passages for refrigerant. From the eye, the refrigerant enters the flow passages formed by the impeller blades, which rotate at very high speed. As the refrigerant flows through the blade passages towards the tip of

the impeller, it gains momentum and its static pressure also increases. From the tip of the impeller, the refrigerant flows into a stationary diffuser. In the diffuser, the refrigerant is decelerated and as a result the dynamic pressure drop is converted into static pressure rise, thus, increasing the static pressure further. The vapour from the diffuser enters the volute casing where further conversion of velocity into static pressure takes place due to the divergent shape of the volute. Finally, the pressurized refrigerant leaves the compressor from the volute casing. Axial flow: It was recognised that the axial flow compressor had the potential for both higher pressure ratio and higher efficiency than the centrifugal compressors. Another major advantage for jet engines was the much larger flow rate possible for a given frontal area. Axial flow compressor consists of a number of stages, each stage consisting of a number of rotor blades followed by a number of stator blades. The working fluid is initially accelerated by the rotor blades and then decelerated in stator blades. The process is repeated in as many stages as are necessary to yield the overall pressure ratio. Further rotary compressors can be classified into five types: i. Screw compressors: Rotary screw compressors are also of positive displacement type. Two meshing screw rotors rotate in opposite directions, trapping refrigerant vapour, and reducing the volume of refrigerant along the rotors to the discharge point. Rotary screw compressors use two meshing helical screws, known as rotors, to compress the gas. In a dry running rotary screw compressor, timing gears ensure that the male and female rotors maintain precise alignment. In oil flooded rotary screw compressor, lubricating oil bridges the space between the rotors, both providing a hydraulic seal and transferring mechanical energy between the driving and driven rotor. The only limitation with rotary screw compressor is that lubricant carry-over to delivered air requires proper maintenance. ii. Scroll compressors: A scroll compressor (also called spiral compressor), is a device for compressing air or refrigerant. Many residential central HP and A/C systems employ a scroll compressor instead of the more traditional rotary and reciprocating compressors. A scroll compressor uses two interleaving scrolls to pump, compress or pressurise fluids such as liquids and gases. The vane geometry may be involutes, Archimedean spiral or hybrid curves. Often, one of

1: Eye, 2: Impeller, 3: Refrigerant passages, 4: Vaneless diffuser, 5: Volute casing and 6: Refrigerant discharge

Figure 2: Classification of compressors based on working principle

Figure 3: Various components of a centrifugal compressor and its working principle


fundamentals

Figure 5: Schematic diagram and Working of a screw compressor

Figure 4: Schematic diagram of an axial flow compressor

the scrolls is fixed, while the other orbits eccentrically without rotating, thereby, trapping and pumping or compressing pockets of fluid between the scrolls. iii. Vane Compressors: A rotary-vane compressor is also known as a rotary piston compressor because the function of the vane is similar to that of a piston (shown in figure 7). The fixed casing is known as a cylinder. The vane splits the space between the cylinder and the rolling piston into two sections (suction and discharge). As the rolling piston rotates, these two volumes are increased and decreased to achieve gas suction, compression and discharge. This compressor type can also be sub-classified by the drive speed (constant and variable) and number of vanes. Each operation cycle includes five actions: start, suction, compression, discharge and end. Each crankshaft rotation can achieve these five actions by average. The capacity can be adjusted through cylinder unloading or inverter drive.

Reciproacating Compressors

is equal to or slightly less than the evaporator pressure. Similarly, the pressure in the outlet manifold is equal to or slightly greater than the condenser pressure. The purpose of the manifolds is to provide stable inlet and outlet pressures for the smooth operation of the valves and also provide a space for mounting the valves. The valves used are of reed or plate type, which are either floating or clamped. Usually, backstops are provided to limit the valve displacement and springs may be provided for smooth return after opening or closing. The piston speed is decided by valve type. Too high a speed will give excessive vapour velocities that will decrease the volumetric efficiency and the throttling loss will decrease the compression efficiency.

Ideal Reciprocating Compressor

An ideal reciprocating compressor is one in which: • The clearance volume is zero • No pressure drops during suction and compression • Suction, compression and discharge processes are isentropic in nature Figure 9 shows the schematic of an ideal compression process on pressure-volume and pressure-crank angle (θ) diagrams. Different processes involved in the cycle of operations of the ideal reciprocating compressor are as follows: Process D-A: This is an isobaric suction process, during

Reciprocating compressors are of positive displacement type where the working fluid is generally taken as air. They work on the principle of slider crank mechanism. Reciprocating compressors consist of a piston moving back and forth in a cylinder, with suction and discharge valves to achieve suction and compression of the working fluid. The suction (inlet) and the discharge (outlet) valves open and close due to pressure differences between the cylinder and inlet or outlet manifolds respectively. The pressure in the inlet manifold

Figure 6: Schematic diagram and theory of operation of a scroll compressor


Figure 7: Schematic diagram of a vane compressor

fundamentals

Figure 8: Schematic diagram and working principle of a reciprocating compressor

Figure 10: p-v diagram for a single acting reciprocating compressor

Figure 9: P-V and P-θ diagram of an ideal reciprocating compressor

which the piston moves from the Inner Dead Centre (IDC) to the Outer Dead Centre (ODC). The suction valve remains open during this process and refrigerant at a constant pressure Pe flows into the cylinder. Process A-B: This is an isentropic compression process. During this process, the piston moves from ODC towards IDC. Both the suction and discharge valves remain closed during the process and the pressure of refrigerant increases from Pe to Pc. Process B-C: This is an isobaric discharge process. During this process, the suction valve remains closed and the discharge valve opens. Refrigerant at a constant P is expelled from the compressor as the piston moves to IDC.

Condition for Minimum Work

Since, a compressor is power consuming device we demand for minimum work input to the compressor. Different p-v diagrams are drawn for different processes in case of a compressor (shown in figure 10). From the given indicator diagram, it is observed that in case of isothermal process, area under the given p-v diagram is minimum and hence the work input is minimum. However, in actual cases isothermal process is not possible as temperature cannot remain constant throughout the process. So, in general we have to incorporate a practical process which is not isothermal and have to ensure that the work input to the compressor is as minimum as possible. So, there is a terminology known as the isothermal efficiency which compares the work done on the compressor with that of the isothermal work.

Isothermal efficiency of the compressor =

Isothermal Work Indicated Work

Limitations of Reciprocating Compressor • Low mass flow rate • Needs elaborate cooling and lubricant

• Thickness of cylinders should be large because of high pressure ratio • Balancing of the reciprocating parts is very much difficult Figure 11 shows the relation between isothermal efficiency and indicated work (power). It shows that with increase in indicated power, the isothermal efficiency of the compressor decreases. This is due to the reason that practically it is not possible to have any isothermal process and more the process tends to be isothermal more is the isothermal efficiency tending to 100%. Figure 12 shows the relation between isothermal efficiency and discharge pressure. As discharge pressure increases, pressure ratio goes on increasing which ultimately results in decrease of isothermal efficiency.

Vapour Compression Refrigeration System

This is the most widely used refrigeration system which is used in domestic refrigerator, air conditioning plant, ice making plant, cold storages. The working substance used in the refrigeration system is called refrigerant. The choice of refrigerant depends on the applications as well as the performance. A schematic diagram of the refrigeration plant with the basic components only is shown in figure 13. A refrigeration system comprises several basic components such as compressors, condensers, expansion devices, evaporators, etc. Different processes undergoing in the four components are explained with the help of a relevant T-s diagram as shown in Figure 14. Process 1-2: Isentropic compression (s2 = s1) of the refrigerant vapour and this is executed by a compressor. It may be noted that the actual compression in a real system is never isentropic due to the irreversibility associated with the process. The deviation is taken care by defining a term called isentropic efficiency of the compressor. This efficiency term is defined as the ratio of isentropic work and the actual work input. Process 2-3: De-superheating and condensation and at constant pressure. This takes place in the condenser. It may be noted that some pressure drop takes place here due to the flow of the refrigerant through the tubes. Cooling India | April 2018| 43

fundamentals

Figure 11: Graph between indicated power and isothermal efficiency

Process 3-4: Throttling in the expansion valve, h3 = h4. Pressure decreases here from the condenser pressure to the evaporator pressure. It also controls the refrigerant mass flow rate in the cycle. Capillary tube, automatic expansion valve and thermostatic expansion valve are some of the varieties of expansion devices used in vapour compression refrigeration plants depending upon the application. Process 4-1: Evaporation at constant pressure p0, q0 = h1-h4. The refrigerating effect is realized in this device and it is a heat exchanger similar to condenser, but the heat flows from the surrounding medium to the refrigerant inside the tubes.

Role of Compressor in Refrigeration System

The compressor is the ‘heart’ of the refrigerant system and is the component that limits the capacity of a refrigerant system. It is also often the costliest component of any vapour compression refrigeration system. The function of a compressor in a vapour

Figure 13: Flow diagram for vapour compression system


Figure 12: Graph between isothermal efficiency and discharge pressure

compression refrigeration system is to continuously draw the refrigerant vapour from the evaporator, so that low pressure low temperature can be maintained in the evaporator at which the refrigerant can boil extracting heat from the evaporated space. In a vapour compression system, a reciprocating compressor is incorporated where the compression is achieved by trapping the refrigerant into an enclosed space and then reducing its volume.

Performance of Reciprocating Compressors For a given evaporator and condenser pressure, the important parameters of refrigerant compressors are: • The mass flow rate, ṁ of the compressor for a given displacement rate. • Power consumption of the compressor (Wc) • Temperature of the refrigerant at the compressor exit. • Performance under part load conditions. The mass flow rate decides the refrigeration capacity of the system, and for given compressor inlet condition, it depends on the volumetric efficiency of the compressor. The volumetric

Figure 14: T-s diagram for vapour compression cycle

fundamentals is equal to the compressor displacement rate. The volumetric flow of the refrigerant is obtained by multiplying mass flow rate of the refrigerant and the specific volume of the refrigerant vapour at the compressor inlet. The maximum possible volumetric flow rate is the swept volume of the compressor in unit time which can be calculated as

Where n= number of cylinders, N= rotational speed of the compressor, in RPS, D= Bore of the cylinder, in m and L= Length of the cylinder, in m. Finally, mathematically the volumetric efficiency can be written as ṁv1 Volumetric flow rate v = = Swept volume of the compressor

Figure 15: Variation of pressure ratio with compressor discharge temperature

efficiency, v is defined as the ratio of volumetric flow rate of refrigerant to the maximum possible volumetric flow rate, which Shounak Chowdhury Post graduate student, Indian Institute of Engineering Science and Technology, Shibpur, Howrah.

vs

The discharge temperature of the compressor depends on the type of refrigerant used and the type of compressor cooling. This parameter has a bearing on the life of the compressor. Figure 15 shows that for different compressor efficiencies the pressure ratio increases with the increase in compressor discharge temperature. 

Madhu Sruthi Emani Research Scholar Indian Institute of Engineering Science and Technology, Shibpur, Howrah.

Bijan Kumar Mandal

Department of Mechanical Engineering Indian Institute of Engineering Science and Technology, Shibpur, Howrah

LG Recognized for Sustained Environmental Leadership G Electronics has been recognised by the US Environmental Protection Agency (EPA) with the 2018 Energy Star Partner of the Year–Sustained Excellence Award for continued leadership in protecting the environment through energy efficient home appliances and consumer electronics products. “Environmental sustainability is a core business principle at LG. We’re proud of our long-standing partnership with ENERGY STAR and our positive environmental impact in the United States,” said William Cho, President and CEO of LG Electronics North America. “LG is helping American consumers experience ‘Innovation for a Better Life’ by creating products that deliver energy savings to help save money and the planet without sacrificing performance or style.” EPA Assistant Administrator William Wehrum applauded LG for its accomplishments. “By sustaining its ENERGY STAR commitment, LG continues to lead the way for others, proving that when you save energy financial value accrues across the board. LG is part of a distinguished group that has made a long-term commitment to improving public

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health and protecting the environment by eliminating energy waste and associated pollution,” he said. First recognized as Energy Star Partner of the Year in 2012, LG is committed to developing the most innovative and energy-efficient products that provide consumers with superior performance while lessening the impact on the planet, explained Cho, who was previously named by CR Magazine as Responsible CEO of the Year, in large part due to his leadership in energy efficiency and environmental sustainability. According to the EPA, LG is being recognized for “its unwavering commitment to energy efficiency and product leadership across many categories. LG has distinguished itself both as a leading participant in the Energy Star program again and as a strong, impactful partner for Energy Star promotions.” 


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Mechanical Hazards of Refrigeration Equipment We come across cases of personnel trying to open crankcases without releasing the pressure inside and getting burn injuries on their faces and other injuries due to release of hot crankcase oil under pressure…

high-hazard process units), the consequences of overpressure-induced vessel failure can be extreme. The discipline of system safety suggests that hazard control is the best considered in terms of a hierarchy of safeguards. In order of decreasing effectiveness, the system safety hierarchy is: (1) eliminate the hazard, (2) use passive engineering controls to manage the hazard, (3) use active engineering controls to manage the hazard, and (4) manage the hazard with warnings and procedures. To be effective, the process hazard analysis must consider the entire process system and not just one individual component of that system. Depending on the severity of the consequences, it may be best to manage an overpressure hazard with multiple safeguards.

Overpressure Protection any of the mechanical hazards occurring with refrigeration equipment are common with other non-refrigeration equipment. There can be broadly categorised into two types: 1. Over pressurization due to thermal expansion 2. Injuries from flying components which could be a consequence of overpressurization We also come across cases of personnel trying to open crankcases without releasing the pressure inside and getting burn injuries on their faces and other injuries due to release of hot crankcase oil under pressure.

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Overpressure Thermal Expansion Safeguards The hazard presented by the heating of


a trapped liquid is overpressure. If the overpressure generated by thermal expansion exceeds the burst pressure of its container, then a release of the pressurized liquid will occur. The significance of a loss of containment accident depends on the magnitude of its consequence. If the process fluid is a high-hazard material, appropriate safeguards should be implemented. A high-hazard material as considered here poses a significant hazard to health, safety, and surrounding equipment if suddenly released due to vessel failure. Depending upon the mode of failure for the vessel (e.g., leak versus catastrophic/ fragmenting failure), the nature of the fluid (e.g., flammable, above its boiling point, and/or toxic), and the surroundings (e.g., inside an occupied building or adjacent to other

There are several design standards and guidelines that contain requirements for overpressure protection. These documents tend to emphasize two strategies for hazard control, pressure containment (passive engineering control) and pressure relief (active engineering control). In essence, the recommended practice is this: if a liquid can be trapped and heated in a section of piping or within a container, then the designer must either provide a means for pressure relief or he must design that component to withstand the greatest pressure that can be developed. Limitations of the Pressure Relief System A process system typically consists of a network of vessels and piping. Pressure relief devices are incorporated into the design with specific hazard scenarios in mind. It is essential that the design basis for pressure relief is thoroughly understood

risks and documented. As process changes are implemented over the lifetime of the process system, the impact of the change on the pressure relief system must be considered (via the management of change program). For example, most indirect heating systems circulate heat transfer oil through an expansion tank. Pressure relief for the entire flow circuit is often provided only at the expansion tank. Care must be taken to ensure that any process modification does not present the opportunity to trap liquid anywhere in the flow circuit. Guard against Blockages in the Flow Path Flow blockages come in all shapes and sizes. Once a process liquid has become isolated from the pressure relief system, it becomes a potential victim of uncontrolled thermal expansion. Manual block valves, control valves that fail closed, and check valves are obvious forms of flow blockage in a piping circuit. However, other blockages may not be so obvious. For example, in refrigeration systems with secondary coolants it may be possible to freeze a heat exchanger to the extent that it completely blocks the flow of the secondary coolant. The potential for nonobvious hazard scenarios underscores the importance of conducting a systematic process hazards analysis. Know/Verify the Design Pressure of Each Piping Component Just like a chain will fail at its weakest link, so too in any given piping circuit, the component with the lowest design pressure will be the first component to fail under overpressure. The lowest design pressure for a component will usually dictate the design pressure for the system. The set point for the pressure relief system should be based on protecting the component with the lowest design pressure. Conclusions The heating of a trapped liquid is a well-recognized hazard scenario, but it is sometimes overlooked. This seemingly minor source of overpressure can actually result in a catastrophic accident. The two primary strategies for protecting against this overpressure hazard are pressure

Figure 1.1: M V Canmar Spirit

containment and pressure relief. There are numerous design standards and guidelines that document good engineering practices for implementing these strategies. To be effective, the process hazard analysis must consider the entire process system and not just one individual component of that system.

Rupture of Tank or System Cylinders or systems without pressure relief devices could break if the refrigerant pressure inside were to exceed the strength of the cylinder or system component. This type of failure can be quite hazardous if the refrigerant is at a high pressure or solid material is blown loose. Containment failures are caused by one of two things: The refrigerant pressure has increased above the pressure rating of the cylinder or system, or something has happened to the cylinder or system so that it will no longer hold normal refrigerant pressure. Elevated refrigerant pressure can be caused by exposure to heat. Refrigerants with pressures similar to R-12 will develop more than 500 psia at temperatures above 200°F. Refrigerants with pressures similar to R-502 will achieve the same pressures at about 150°F. Hydrostatic pressure also can develop quickly in a confined volume that has been completely filled with liquid refrigerant, for example liquid-full hoses between shut valves or an overfilled recovery cylinder.

Refrigerant tubing, hoses, system components and some refrigerant cylinders surely would fail at some elevated pressure without certain safety provisions. Various pressure relief devices are used to lower the pressure back to safe limits by releasing some or all of the refrigerant. Valves on many refrigerant cylinders are fitted with spring-loaded pressure relief valves. These are typically set to release pressure somewhere above typical refrigerant pressures at normal use or transportation temperatures, but below the maximum service pressure of the cylinder. When the pressure is reduced to a safe level, the valve should close itself. Other cylinders or storage vessels are fitted with burst discs as the pressure relief device. These are pieces of metal designed to break at some preset pressure, again lower than the maximum service pressure of the container. In the case of a burst disc, the entire contents of the container will be released. This is also the case with a fusible plug, which is designed to melt at a certain temperature. It is used to relieve the pressure in a tank or system in a fire situation before the pressure gets high enough to burst the tank, tubing or system component. Damaged or weakened refrigerant cylinders or system components may fail at pressures lower than originally specified. Cooling India | April 2018| 47

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Figure 1.2: Damage to Air Compressor due to Explosion in M V CANMAR SPIRIT

Physical abuse such as dents, scratches, rust, bulges or exposure to excessive heat can reduce the strength of joints or the metal itself. Materials originally designed to hold hundreds or thousands of psi pressure might now fail at typical refrigerant pressures. In the case of damaged cylinders, the pressure relief device shouldn’t be relied upon for protection; the cylinder should be repaired and retested or discarded. The best way to avoid pressure-related hazards is to always use cylinders and system components that have the correct pressure rating for the refrigerant you’re using. The table given below lists the typical cylinder service pressures that manufacturers and distributors use for various refrigerants. Pressure ratings for system components must be chosen based on the application and expected service pressures for the intended application. Pressure ratings are also based on the refrigerant chosen. Always check for signs of damage or excessive wear before filling recovery cylinders, picking up new refrigerant cylinders or attaching new parts to a system.

Service Pressures and Test Pressures Typical test pressure is 2 to 2.5 times the service pressure. Service pressure is stamped or printed on the cylinder, sometimes preceded by a number and letter such as “3A400” or “3B260”. Cylinder Service Refrigerant Pressure (psig) R 12 260 R 22 260 R 500 260 R 502 260


Refrigerant R 114 R 134a R 401a R 401b R 402a R 402b R 404a R 406a R 407a R 407c R 408a R 409a R410a R 414b R 416a R 507

Cylinder Service Pressure (psig) 260 260 260 260 350 300 300 260 300 300 300 260 400 260 260 300

Table 1.1 Cylinder Service Pressures of Various Refrigerants

Incident 1: Air Compressor Explosion on CANMAR SPIRIT

Source: Transportation Safety Board of Canada Marine Investigation Report M99L0011

On 27 January 1999, MV CANMAR SPIRIT was up bound in the Port of Montreal, Quebec, making way towards section 78 for berthing and ensuing cargo operations. As a normal part of the duties during maneuvering, a member of the engine-room crew was detailed to start two of the ships main air compressors. After having started the No 1 compressor without incident, he proceeded to initiate the start-up of the No 3 compressor. During the start-up sequence, a sudden and violent over-pressurization occurred within the compressor. Damage to the compressor included burst cooler tubes in the second-stage (after) cooler, burst compressor casing in way of the cooling

water chamber, and a flayed flexible delivery airline. The second-stage air cooler cover also burst and fragments of this piece were projected outward in a shrapnel-like fashion, seriously injuring the crew member. As the CANMAR SPIRIT had not yet berthed, a harbor tug was used to evacuate the injured crew member under the supervision and assistance of trained ambulance technicians. The crew member was later pronounced dead at the hospital. The Board determined that the No 3 compressor on the CANMAR SPIRIT experienced a severe and near instantaneous over-pressurization due to the system delivery valve remaining closed while the compressor was started. This omission, combined with the malfunctioning air relief valves, created a closed circuit in which certain components of the compressor could not withstand the everincreasing pressure. A factor contributing to the accident was the less-than-adequate maintenance of non-return valves. Details On the afternoon of 18 January 1999, the CANMAR SPIRIT left Lisbon, Portugal, bound for Montreal. By the early afternoon of 27 January 1999, after an uneventful ocean passage, the vessel was approaching section 78 in the Port of Montreal to berth and commence cargo operations. In the engine-room, the crew had been mustered to maneuvering stations and was going about their various tasks. The chief engineer was present in the control room with the officer of the watch (OOW). At approximately 1345 Eastern Standard Time, the duty greaser was detailed to

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risks start up main air compressors Nos 1 and 3. After starting the No 1 compressor without incident, he proceeded to start the No 3 compressor. Shortly after the initiation of the start-up procedure, at approximately 1400, a sudden and violent over-pressurisation occurred within the compressor. An explosion-like noise was heard throughout the vessel and a white vapor was observed in the vicinity of the compressor by the crew members in the control room. The OOW went immediately to the scene of the accident and saw the duty greaser walking uneasily and then collapsing close to the No 1 compressor, approximately eight meters from the scene of the accident. It would appear that the victim was in the process of closing the first and second-stage purge drain valves when the over-pressurisation occurred. The act of closing the purge drain valves positioned him near and just slightly to the right of the second-stage air cooler cover. The complete and violent failure of this piece of equipment during the overpressurisation of the compressor caused serious injuries to the duty greaser that later proved to be fatal. First aid was administered to the injured crew member where he lay by the ships personnel. Montreal Marine Communications and Traffic Services was advised of the situation and the tug OCEAN INTREPID with ambulance technicians on board was called to the scene immediately. By 1418, the ambulance technicians had boarded the CANMAR SPIRIT by way of the tug and were administering first aid to the victim. At approximately 1455, the injured crew member was evacuated via the tug ashore, and then to a local hospital under the supervision and assistance of the ambulance technicians. Once the injured crew member had been evacuated, the berthing operation of the CANMAR SPIRIT was successfully completed. Upon arrival at the hospital, the injured crew member was pronounced dead by the hospital authorities. Findings 1. The duty greaser started the No 3 compressor without opening the system delivery valve for this

compressor. 2. The pressure relief valves on both the first and second stages of the failed compressor were blocked by sooty, oily residues and thus, rendered inoperable. On the other, two compressors, half of all the relief valves did not work properly, when tested, due to similar residues. 3. The non-return valves on all three compressors leaked, thus, allowing compressed air to return to the compressors from the air receivers when the compressors were not operating. This created the necessity for human intervention since the delivery valves had to be opened and closed manually before and after each compressor start and stop sequence. 4. The seat and spring plates of the failed compressors non-return valve appeared to be in good condition; however, there was an extensive buildup of oily, sooty residues in the valve. This is the most probable cause of the leaking condition. 5. The Jabsco water pump had been operating at reduced capacity due to five previously broken impeller vanes, but no evidence of overheating was observed. 6. The fracture surfaces on the secondstage outlet cover were consistent with an instantaneous failure with no evidence of pre-cracking or previous repair. The cover fractured into many fragments that were projected outward at high velocity. 7. The duty greaser sustained fatal injuries from fragments of metal projected out at high velocity. 8. The first-stage cooler tubes were consistent with manufacturers specifications in all respects. They did not fail subsequent to the overpressurisation of the compressor. 9. Of the 33 second-stage cooler tubes, 18 failed during the over-pressurization of the compressor. 10. The second-stage cooler tubes did not meet manufacturers specifications with respect to material, outside diameter and wall thickness. Wall

thickness was found to be, on average, half that of manufacturers specifications. 11. The second-stage cooler tubes showed no evidence of overheating or combustion. The over-pressurization was most likely due to the compressor working against a closed circuit created by relief valves not operating properly and a closed system delivery valve. 12. The cooler tubes revealed corrosion pitting attributable to the less-thanadequate use of anti-oxidant additives in the cooling water. This does not seem to be a significant factor in this accident. 13. The compressor casing burst open in way of the cooling water chamber due to a severe and near instantaneous over-pressurisation. The cooling water relief valve seems to have been operable but in all likelihood could not handle the rate of expansion associated with the complete and near instantaneous failure of the highpressure cooler tubes at pressures at or above 4,000 psi. 14. The majority of the engine-room crew and the master were experienced mariners but this was their first tour of duty on board the CANMAR SPIRIT. 15. Some of the crew members reported being under pressure and stress following the accident but relief and assistance were neither requested nor offered. Causes The No 3 compressor on board the CANMAR SPIRIT experienced a severe and near instantaneous over-pressurisation due to the system delivery valve remaining closed while the compressor was started. This omission, combined with the malfunctioning air relief valves, created a closed circuit in which certain components of the compressor could not withstand the ever-increasing pressure. Contributing to the accident was the less-than-adequate maintenance of non-return valves. Incident 2 – Operator injury due to pressure build up due to power outage during Lyophilization Cooling India | April 2018| 51

risks There is a case study that has resulted in significant business interruption and severe burn injuries to an operator. Lyophilization, also referred to as freeze-drying, is the process of removing moisture from a pharmaceutical product by first freezing it and then by subjecting it to a vacuum. This process promotes the direct phase change from solid ice to water vapor without a transition through a liquid phase—a process known as sublimation. In a conventional drying process, a product is heated at atmospheric pressure, requiring much higher temperatures, to promote this phase change. Lyophilization benefits pharmaceuticals by increasing product shelflife without heating, which can have a deleterious impact on product quality and/ or performance. The subject freeze-dryer was composed of a process chamber, a condensing unit, vacuum pumps, and a utility skid. The utility skid used liquid nitrogen to cool silicone oil that was used as a heat transfer fluid. The cold silicone oil was circulated through a heat exchanger in the process chamber to chill the product. The silicone oil was also used to cool the condenser. After the product was chilled, the vacuum pumps would lower the pressure in the process chamber causing water to sublime as vapour from the product. This vapour was then deposited on plates in the condenser. Electric immersion heaters were also installed in the silicone oil flow circuit for additional temperature control. On the day of the incident, a power outage occurred on the freeze-dryer’s control system power supply. As a result of the loss of power, a number of key sensors and control elements were unavailable to the programmable logic controller. In response, the control system managed a chain of events that led to the freeze-up of the oil-nitrogen heat exchanger and the call for heat in the electric heater. The silicone oil inside the heat exchanger froze, forming a solid plug. There was liquid silicone oil trapped between the frozen oil in the heat exchanger and the check valves. The control system initiated a call for heat, which resulted in 52 | Cooling India | April 2018

the thermal expansion of the trapped liquid oil. This resulted in the catastrophic rupture of the housing for the electric heater. The ejected oil ignited causing a flash fire and serious injury to an operator.

General Precautions to Prevent Excessive Pressure Build-up at Elevated Temperatures • Storing refrigerant cylinders in upright position. • Moving larger cylinders only when protective cap is in place. • Securing larger cylinders to carts specially designed for moving cylinders • Wearing gloves and eye protection at all times. • Take precautions to ensure that refrigerant cylinders do not topple and fall over. The valve cover may become loose and fall off. The valve stem may break off causing the cylinder to become a projectile with uncontrolled trajectory. • Injuries from flying components We come across many cases where operating personnel have got injured, sometimes fatally because they were directly in line with flying components which could be a consequence of overpressurisation among other causes.

Incident 1: Injury to third engineer due to flying air whistle valve piston A team of Second Engineer and Third Engineer were working on the ship’s air whistle on the mast. The air bottle in the Engine Room was isolated by closing the main air stop valve and also the individual air whistle valve. The main piston of the air whistle was stuck in one position and not moving freely. After trying to extricate the piston, they put some lub oil to ease up the piston and went for lunch. After finishing lunch, before anyone else, the third engineer went straight to the air whistle and tried to ease up the piston using a screw driver. Suddenly, the piston (weighing about half a kilogram) popped up and flew up like a bullet. Unfortunately, the third engineer’s face was directly and vertically above and the flying piston hit him under his eye. He had to be hospitalized immediately and got 6 stitches above his eye. Luckily, there was no damage to the

eye itself. There were three points to be noted in the incident: • His face was directly in the trajectory path of the flying component. • Both the air valves from the air bottle which were in series were leaking. In spite of closing them, there was a pressure built up over a period of time. • The lubrication eased up the piston and the moment, he applied the screw driver, the piston came loose and flew off. Lessons learnt the hard way from this incident: • Always make a judgement of the flight path or trajectory of the flying component and keep out of the path. Easier said than done. • Never trust any valve in the Engine room. Assume that valves don’t hold and plan your work to be safe. Drain lines to ensure there is no pressure build up.

Incident 2: Engineer injured due to flying valve bonnet Source MARS Report No. 200337 The air conditioning compressor on board had developed a leak and was being investigated by the ship’s staff. Having come to the conclusion that the discharge valve of the compressor was leaking through the gland, it was decided to replace the valve bonnet with a spare one on board. The complete system was isolated and gas was collected in the receiver. Having convinced themselves that there was no gas in the system, the staff concerned commenced dismantling the valve bonnet. Suddenly the valve bonnet blew off and struck the Engineer in the stomach and punctured his liver resulting in his death. On investigating the cause of the accident, it came to light that: • The Engineer, due to inexperience, released all the bolts holding down the bonnet and tried to crack the joint using a hammer and screw driver. • The Engineer did not seem to be aware that pressure could still be in the system even though the discharge gauge did not indicate any pressure. • He did not take the precaution of

risks staying away from the valve while releasing the flange joint and was right in front of the valve, while dismantling. • No senior Engineer was supervising the job even though the concerned machinery is always under pressure. This unfortunate incident certainly occurred as a result of poor safe practices. It must be emphasised here that senior staff has a responsibility in supervising and educating the junior staff in taking sufficient safety measures, especially, while working on machinery under pressure.

General Mechanical Equipment Safety Precautions • Never wear loose clothing or jewelry when working near moving mechanical parts. They can get caught in belts, pulleys and fans causing serious injury • Always use eye protection when working near mechanical machinery • Do not try to stop moving machinery with hand. This may cause injury to fingers.

• Observe standard safety practices when moving heavy or awkward objects: – Get help from co-workers if necessary. – Use hand carts and other equipment for moving heavy components. – Make sure the component is secured on the hand cart so that it does not fall over. • Use proper lifting techniques when lifting heavy parts: – Lift with legs with knees bent and not with back muscles. – Never twist from the waist when carrying items. – Rotate the entire body in the direction you wish to go. – Wear protective lifting gear (back brace, gloves etc.) whenever required. • For material handling, whenever possible use mechanical lifting devices like chain blocks, making sure that the

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individual components in the lifting chain work within safe working loads. Ensure that the place is adequately ventilated before commencing repair work on any refrigeration or airconditioning machinery. Refrigerants will displace oxygen as they ae heavier than air. This may cause suffocation. If special leak detectors and alarms are fitted, make sure they are working properly. Avoid breathing in refrigerant vapors. Be careful when handling chemicals used for water treatment and for cleaning equipment like condensers etc. Follow manufacturer’s guidelines for use, disposal and first aid. 

C Maheshwar

Anglo Eastern Maritime Academy, Karjat, Mumbai

First IoT Air Cooler earing up for the Indian summer season, Bajaj Electricals, India’s leading consumer durable and lighting company, recently launched the first of its kind IoT enabled air cooler– Bajaj COOL.iNXT. With the launch of this IoT product, Bajaj Electricals aims to improve customer’s experience through smar t technology and intuitive designs. In the next two years, the company expects a huge potential for IoT enabled air coolers, not only from the residential space but also commercial. The unique features of Bajaj COOL.iNXT can be accessed through a smartphone from anywhere in the world. The specially designed app provides complete control to its unique features and functions at the fingertips of the user making the cooling experience smart and convenient. Being the pioneer of new age intelligent IoT technology,

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Bajaj COOL.iNXT has the following features that differentiate it from other air coolers: • 3 Methods of Control: With the state-of-the-art mobile app; IR remote and digital control panel • Easy ‘Wi-Fi & Internet Enabled’ operation • Intelligent Sensor that reads the temperature and humidity • Auto mode to automatically adjust the fan and cooling speed on the basis of the temperature and humidity • 5 level speed control and 4 cooling levels • Digital control and display panel • Digital low water level indicator • Honeycomb cooling media for efficient cooling • Ice Chamber for faster cooling Anant Bajaj, JMD, Bajaj Electricals, speaking on the launch said, “We are extremely excited and proud to launch India’s first IoT enabled Air Cooler. Real intelligence is when technologies interact with one another to make things effortlessly happen. We want the technology to earn a permanent place in everyday life, where IoT technology will play a crucial role making the process of cooling homes and commercial spaces smarter, effective and effortless.” Recently, the research and development center has been certified Platinum Status for Leadership in Energy and Environmental Design (LEED) by the USGBC. 


case study

Delivering Environmentally Focused Installation Ten Trinity Square project involved the design and installation of multiple diverse cooling and heating systems at the iconic central London hotel development Ten Trinity Square...

he systems and services within the hotel were designed to provide the highest practical levels of energy efficiency whilst delivering an environmentally focused installation with maximum operational performance and value. With these objectives in mind the

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projects Food Service consultant, Gareth Sefton of SHW Design, invited Green Cooling into the project due to their expertise in providing environmentally friendly refrigeration systems and their previous experience working together on similar demanding projects. In terms of the projects Mechanical

Consultants, Green Cooling worked alongside Waterman Group and Qoda in providing specification and system designs for a range of cooling and heating related areas within the project. Green Cooling provided a combination of design, specification, equipment and installation services to the project across a number of areas: • CO2 Refrigeration providing the Food Service medium and low temperature cooling supplies • High specification cold room refrigeration systems and associated ancillaries • Refrigeration waste heat recycling systems • Computer room & IT cooling systems • Air-conditioning to critical switchgear/ transformer areas • Air-conditioning within front of house/ residential areas • Front of house bespoke wine display systems • Pool heating via recycled waste refrigeration energy • Pool/Spa surround floor warming and sauna floor cooling From Green Cooling’s perspective the services and equipment provided to this project demonstrated capability across a number of defined areas. The systems provided include the latest CO2 refrigeration plant supplying critical food service cooling, with the recycled waste heat from refrigeration being used to heat the hotels swimming

case study pools and Spa areas. Within the kitchen, refrigeration is supplied to fourteen high specification walk-in cold rooms/freezers plus preparation areas. A CO2 water/glycol chiller provides cooling to front of house wine display units, plus a high specification refrigerated wine wall feature was also designed & provided by Green Cooling within one of the hotels signature restaurants. Within the Pool & Spa area an under floor system was provided, this delivers pool surround floor warming along with low temperature underfloor cooling to the sauna area. In terms of the hotels IT and Computer Rooms, high specification Computer Room Air-conditioning units (CRAC units) were provided which supply critical computer/data room cooling. In addition numerous VRF systems were provided to deliver cooling and heating throughout various areas of the building, from the electrical transformer rooms through to Ten Trinity Squares highest value apartment. Therefore a very diverse and varied list of requirements were satisfied, all centred around Green Cooling’s objective of delivering cooling and heating systems which provide the most efficient levels of performance with the highest levels of operational capability. Ardmore Group’s Construction Director on the Trinity Square project was Steve McGee who comments, ‘Ardmore were very pleasantly surprised by the professionalism shown by Garry and David during the preconstruction phase, which proved to be tricky given the challenges of the building. Installation proved to be seamless, as GC kept close to progress onsite and pounced at the opportune time to install their equipment, when the window of opportunity arose’, continuing, ‘Finally at commissioning stage GC were very efficient, and they really shone when hiccups in the water chiller plant impacted their equipment, by giving immediate remote support, ensuring systems were back online efficiently’. Reflecting these comments, the Green

Cooling in-house design and specification teams provided the project with a complete support service that met the dynamic nature of this fast moving development. This diligent approach is a fundamental part of the Green Cooling service and as this project demonstrates, this approach enabled value to be added at every stage of the project across several different disciplines.

Equipment & Services • 2 x 100kW Twin Energy GC MultiCompressor Packaged CO 2 Refrigeration Units providing 100% contingency based food service cooling, delivering medium and low temperature supplies to chilled cold rooms and freezers • 14 x High specification cold room refrigeration systems, delivered via 28 x high efficiency cold room evaporators (twin units per cold room delivering 100% contingency) • 1 x Monitoring system with leak detection throughout, providing both local and web based visibility of all the refrigerated elements of the project. This system provides operational control and remote access, assisting the operator in achieving optimal performance. • 1 x 4,000 litre GC Thermal Hub, Refrigeration Waste Heat Recycling System, providing pool & spa heating • 1 x 50kW GC CO2 Secondary Water/ Glycol Chiller providing front of house display refrigeration • 1 x GC Wine Wall Feature Display with 5C to 18C individual temperature control across four separate compar tments/zones to enable champagne, white and red wine to be presented • 2 x 12mm Nuheat Low Profile Pex Underfloor Heating Systems to provide floor warming to the Pool surround areas • 1 x 20mm Rehau Pex Multi Zone Low Temperature Floor Cooling System to the Sauna area • 2 x 50kW Stulz Computer Room AirConditioning (CRAC) Units providing

100% contingency based cooling to the hotels data room • 12 x Mitsubishi/Daikin VRF/AirConditioning Systems ranging from 10kW to 35kW throughout various critical areas • 2 x 15kW GC CO2 Air-Conditioning Systems, maintaining 12C within the residents’ club/wine store area

Application Ardmore Construction was the projects main contractor, completing and handing over the prestigious Ten Trinity Square in May of 2017. Having taken the project on a design & build basis from its former use and delivering it as a Five Star Hotel and Spa which incorporates Prestigious Apartments, a Private Members Club and several Signature Restaurants, Ten Trinity Square is set to become one of London’s premier destinations. Constructed in 1922, Ten Trinity Square was historically the home of the Port of London Authority. Overlooking Tower Bridge and with sweeping views down the Thames to the East; this iconic building can best be described as one of the most striking structures in London. During its illustrious past the building hosted the first meeting of the United Nations in 1946 and took a starring role in the 2012 James Bond film Skyfall. Hence it is befitting that the building now starts a new lease of life as a high quality destination hotel competing with the Shard for the top spot on the East side of the city.  Credit: Green Cooling Cooling India | April 2018| 55

processing

Post-harvest Handling & Storage of Potato An ideal storage environment must be provided if the tubers are to be stored up to 10 months. Tubers go through four different storage phases (curing, cooling, long-term storage and marketing), each requiring a different environment. The purpose of potato storage is to maintain tuber quality and provide a uniform flow of tubers to fresh market and processing plants round the year….

otato, popularly known as ‘King of Vegetables’, has emerged as the fourth most important food crop in India after rice, wheat and maize. Indian vegetable basket is incomplete without potato. Currently, India is the third largest

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producer of potatoes in the world. The production level of the country hovers around 47 million tons. The major potato growing states are Uttar Pradesh, West Bengal, Punjab, Bihar, Haryana, Madhya Pradesh, Gujarat and Maharashtra. More

than 90% potato crop is grown in winter season (Rabi) under assured irrigation facility from October to March. The rest is being taken up during rainy season (Kharif).

processing otherwise tubers can become susceptible to rot diseases. • Harvest the crop after 10-15 days of haulm cutting. • Harvesting can be done by tractor drawn potato digger or manually with help of spade or khurpi.

Drying and Curing

Figure1: Harvesting of potato with digger

Nutritive Value The constituents of potato per 100 gms. Sl.No. Constituents Weight (grams) 1. Water 74.70 2. Carbohydrates 22.60 (Starch and Sugar) 3. Proteins 1.60 4. Fibre 0.40 5. Fat 0.10 6. Minerals 0.60 Source: Potato in India, Central Potato Research Institute (CPRI), Shimla

The Minerals and Vitamins Potato is given below: Sl. No. Minerals / Vitamins Content 1. Calcium 2. Copper 3. Iron 4. Magnesium 5. Phosphorus 6. Potassium 7. Sodium 8. Vitamin C 9. Thiamin 10. Riboflavin 11. Niacin 12. Total Folate 13. Pyridoxine

as available in (mg/100 gm of fresh weight) 7.7 0.15 0.75 24.2 40.3 568.0 6.5 4.0 – 25.0. 0.18 0.01-0.07 0.4 –3.1 5.0-35.0 0.13-0.25

90 percent of the potato crop in the country is harvested during January-February from the Indo-Gangetic plains comprising the states of Punjab, Haryana, Uttar Pradesh (UP), Bihar, West Bengal, Madhya Pradesh (MP) and Gujarat. In these regions, the harvest is followed by rising temperatures of hot and dry summer and further by warm and humid rainy season. Since potato tubers contain about 80% water, under such circumstances, a semiperishable commodity like potato, cannot be stored for more than 3-4 months without refrigeration because of very high losses to the produce due to shrinkage, sprouting and attack by microorganisms. Following harvest and post harvest handling conditions should be carefully controlled.

Harvesting Follow the practice of dehaulming cutting of haulms /aerial parts by sickle or destroying by machines, when the crop attains 80-90 days and when the aerial part of the plant turns yellow. • Always harvest in dry weather. • Stop irrigation about two weeks before dehaulming. • Avoid bruising and skinning of tubers

The harvested potato should be cured in the field. For optimum suberization, curing is essential for healing the wounds of tubers resulted from cutting and bruising during harvesting. Exposure to sun causes the greening of potatoes. Always dry the harvested tuber in storage shed. All the damaged and diseased tubers should be removed during sorting. The following care should be taken during drying: 1. Always dry the harvested tuber quickly to remove excess moisture from the surface of tubers for improving their keeping quality. 2. Always dry the harvested tuber in storage shed, expose to sun causes the greening of potatoes. 3. Do not store the tubers immediately if they are exposed to rain after harvest. The following care should be taken during curing: 1. Always follow the curing process at 25 degree centigrade with a 95 per cent relative humidity, 2. For optimum suberization, curing is essential for healing the wounds of tubers resulted from cutting and bruising during harvesting. 3. All the damaged and diseased tubers should be removed during sorting.

Packaging Handling and packaging of potatoes

Source: Potato in India, Central Potato Research Institute (CPRI), Shimla

At present 1210 million people of India consume potato (approx. 68.5%) mainly as vegetable. Potato production in India has shown a steady increase in the last 50 years. Increase in production, often resulting in gluts at harvest, has led to several post-harvest issues like storage and proper utilization of the produce. About

Figure 2: Field curing of harvested potatoes


processing

Netlon bag

Jute bag

Netlon retail bag

Figure 3: Packaging of potato

are done generally on farm. After harvesting, the tubers are kept in a heaped condition temporarily and covered with straw. After a few days, sorting is done for separating the diseased and cut tubers. The sound tubers are packed in hessian cloth bags or nettlon bags. The ordinary hessian bags are used for packing potatoes with a capacity of 80 kgs, 50 kgs and 20 kgs. The nettlon bags made of plastic net are used to pack 25 kgs potato and preferred for export purpose.

Grading The different grades of potato as suggested by Directorate of Marketing and Inspection, Faridabad are as under: Size Code Equatorial diameter in mm. Size Code Equatorial diameter in mm A 18.1-28.0 B 28.1-45.0 C 45.1-65.0 D 65.1-80.0 E more than 80

of market functionaries increases, they add cost to the commodity in the marketing channel which results in the fall of producers show in consumer’s rupee. Farmers are advised to make their own cooperative groups or Farmers Producers Organizations and follow standard postharvest handling practices for self marketing of produce. Various Government agencies like National Horticulture Board, National Horticulture Mission and Ministry of Food Processing and Industries provide financial assistance for creation of postharvest and cold chain infrastructure for horticultural crops.

Storage of Potatoes An ideal storage environment must be provided if the tubers are to be stored up

Note: The size code ‘A’ shall be marked as ‘Baby Potato’.

Grading plays an important role in marketing of potato. The potato should be packed in different bags as per recommended grades before marketing. Potato marketing in India suffers from severe constraints like wide price fluctuations, existence of large number of middlemen, storage and transportation bottlenecks and lack of other marketing infrastructures. Indian potato marketing system is not efficient, integrated and is not in a position to face the emerging challenges of potato production and utilization. Studies on marketing margins or price spread reveal that as the number 58 | Cooling India | April 2018

Figure 4: Storage of potatoes in a cold store

to 10 months. Tubers go through four different storage phases (curing, cooling, long-term storage and marketing), each requiring a different environment. The purpose of potato storage is to maintain tuber quality and provide a uniform flow of tubers to fresh market and processing plants round the year. Good storage should prevent excessive dehydration, decay and sprouting. It should also prevent high sugar concentrations which result in dark colored fried products. Temperature, humidity, and air movement are the most important environmental factors affecting storability. Temperature requirements are determined by the intended use of the potatoes. Tubers should always be kept in the dark since very small amounts of light will

processing gradually cause greening. Lights should not be used more than absolutely necessary. Surface greening is due to chlorophyll formation and is harmless. However, its presence in potatoes is undesirable because of marketing restrictions and the fact that at times an alkaloid called solanine increases with the chlorophyll. Solanine and other glycoalkaloids cause potatoes to have a bitter, undesirable flavor. Greening develops slowly in the light at 4°C or below but develops rapidly at 20°C. Potatoes are usually held in bulk piles 8 to 20 feet deep. Some are stored in pallet boxes for short periods. Pressure bruise and internal black spot are substantially lower with pallet storage but decay is often increased because of poor air circulation within boxes/bags.

browning (an undesirable browning of the chip colour) during frying. Temperature changes in storage should be gradual and not exceed recommendations for various product uses. The rate of downward ramping of storage temperature for potatoes intended for processing should follow guidelines established by the processing industry. In general, temperature reductions should not exceed -1.7°C per day when cooling to specified holding temperatures. This gradual temperature reduction helps eliminate changes in the sugar content of tubers that can affect processed product quality. For processing potatoes, it is critical that minimal sugar accumulation occurs. Recommended storage temperature for potatoes for different usage is shown in Table 1.

Temperature

Table 1: Recommended storage temperature of potatoes for different usage

Optimal holding temperatures for potatoes in storage depend on the potato variety and the intended end use of the product. Processing potatoes are generally stored between 6°C and 10°C to limit the concentration of reducing sugars in the tuber tissue. By comparison, potatoes intended for fresh market may be stored between 4 and 10°C, while those intended for seed are usually stored at 3 to 4°C. Although there is usually little consideration of table quality as it relates to storage temperature, the best quality is maintained at 4 to 8°C. Storage temperatures are also used to minimize weight losses caused by respiration and shrinkage. Respiratory losses are usually minimal near 7°C. Tuber weight loss due to respiration alone can equal 1, 5 percent of the total weight over an 8 to 10 month’s storage season. To remain viable and competitive, processors demand high quality potatoes from producers. Therefore, the producers must provide a storage atmosphere that can maintain high tuber quality throughout the storage period. A potato storage manager must minimize the loss of mass resulting from dehydration (moisture loss) and respiration (dry matter loss). At the same time, the storage manager must minimize accumulation of reducing sugars in potatoes that can lead to non-enzymatic

Usage Temp, (°C) Seed potatoes 2-4 Table consumption 4-5 French fry production 6-8 Crisps production 7-9 Flakes, granulates 7-10 Long-term chip storage 10-13 (over 4 months) Short-term chip storage 13

Relative Humidity Most of the tuber shrinkage that occurs during the first month of storage results from water lost before the completion of the wound healing process. Maintaining high relative humidity (r.h.) in potato storage prevents some of the early season tuber dehydration and helps control the total shrinkage loss during the season. Shrinkage loss in storage is directly proportional to the length of the storage season and inversely proportional to the relative humidity conditions maintained within that storage. The current recommendation is to maintain 95% RH. or above for minimizing early storage tuber losses due to dehydration. Free moisture is one of the most common problems traced to rot organism spread in storage. Condensation can become a problem when it occurs directly on the tubers or on any inside surface of the storage.

Maintaining circulation air slightly cooler than the bottom of the pile will help prevent condensation directly onto the tubers. Likewise, condensation on building surfaces can be minimized by providing adequate insulation and making sure there is enough air movement to keep surfaces warm and to evaporate the moisture that collects before it drips onto the potatoes

Carbon Dioxide The quality of many fruit and vegetable crops is enhanced if stored under high levels of CO2 combined with low oxygen. This is not the case with potatoes increased levels of carbon dioxide can be detrimental, promoting sprouting and effectively shortening storage life. Even the small amount of CO2 produced as the potatoes respire during the season can build to unacceptable levels up in a well sealed modern store, so it is always wise to ventilate periodically in stores with few natural leaks. In storage room equipment with a CO2-control system, the desired CO2 levels are maintained by controlling the airflow to the scrubber or by regulating the outflow into the storage area. There are four main reagents, which are commercially used for CO2 absorption. They are water, hydrated lime, activated charcoal, and molecular sieve. In these systems, the O2 levels are usually maintained by introducing outside air into the storage room. Longterm storage atmospheres with reduced oxygen content are detrimental to potatoes. A level of 1.0% CO2 should be considered the upper allowable threshold.

Light A potato tuber accumulates chlorophyll when exposed to light, which turns the tuber green. The longer the tuber is exposed to light, the more greening will occur. The process will not reverse- the green color will not go away- if you then store the potato in a dark place. The green color may be unappealing, but the color itself does not affect the taste of the potato. However, green potatoes can form compounds called glycoalkaloids that develop along with chlorophyll formation. Glycoalkaloids may make the potatoes’ taste bitter. In addition, glycoalkaloids are Cooling India | April 2018| 59

processing inducing the required sprout suppression. This chemical currently is being marketed in India by United Phosphorus Ltd, Mumbai under the brand TM name ‘Oorja’. This commercial formulation is said to contain 50% active ingredient (a.i.) and 40 ml of this formulation is required for fogging of one tonne of potatoes.

Procedure for CIPC Application

Figure 5: CIPC application with fogging machine

potentially toxic if you eat a lot of green potatoes at one time. If a potato has only small portions of green, you can safely remove these sections and eat the potato. Discard potatoes with a high proportion of green skin.

Problems of Potato during Storage Sweetness, Sprouting & Decay In general practice, the seed and ware potatoes are stored by the farmers at low temperature (0-3 °C), which is ideal for suppressing sprouting, but physiological changes at this temperature results in accumulation of sugars in the tubers, giving sweetish taste resulting in lowering the culinary qualities of stored potatoes as well as making them unfit for preparation of French fries. Thus, the stored potatoes fetch lower price in the market compared to ‘Pahari’ potatoes from hilly areas. Storage of potatoes at high temperature (10 ± 2 C and 90-95% RH) coupled with application of sprout-suppressant chemicals like CIPC is a viable technology, which can enhance the storage life, maintain the low sugar levels and improve culinary or processing qualities in the potatoes during storage.

known as CIPC, is an effective sprout inhibitor. It acts by blocking the process of cell division (mitosis). In store, CIPC is currently applied as a hot fog of fine solid particles on the potatoes. The mechanism of action of the applied chemical is believed to involve volatilisation of the deposited solid and subsequent transport of the vapour to the eyes of the tubers

1. The disease free fully cured, mature tubers are loaded in the cold storage and temperature is maintained at 180 C during loading. 2. Temperature of the storage is brought down from 180 C to 100 C gradually in one week. 3. Chlorpropham fog is injected @ 40 ml/tonn using DYNA fogging machine into the storage chamber loaded with potatoes. The first fogging is done at the first sign of sprout growth and second fogging is done 60 days later. Refrigeration is not used when CIPC fog is flushed into store. For this, the refrigeration unit is switched off prior to, during and upto 40 hours after the treatment. Then doors are opened for half an hour after 40 hours to flush out the

Without CIPC application

With CIPC application

Without CIPC application

With CIPC application

What is CIPC? Chlorpropham (Isopropyl – N (3Chlorophenyl carbamates), popularly


Figure 6: Comparison of CIPC treated potatoes and its products

processing


processing

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processing accumulated gases. Thereafter, the temperature of cold storage is maintained at 10 ± 2°C and 90-95% RH. The chamber should be completely leak proof to ensure that there is no loss of refrigeration during storage period; otherwise there will be more consumption of electricity to maintain uniform temperature. Humidity should be maintained at 90-95% level inside the chamber to avoid shrinkage in the treated potatoes. Humidifier should be installed to get optimum humidity level. The studies on storage of four cultivars of potatoes viz. Kufri Jyoti, Kufri Chanderamukhi, Kufri Badshah and Kufri Satluj were carried out at Punjab Horticultural Post-harvest Technology Centre. The potato tubers were fog treated with Oorza @ 40 ml /ton. The first dose was given just at the initiation of sprout growth and second 60 days later. During each fogging the refrigeration unit was kept off for 40 hours. After 40 hours, the accumulated gases were flushed out from the chamber and temperature of the storage was maintained O at 10 ± 2 C and 90-95% RH. It was noticed that these cultivars can be stored successfully upto six months without much loss of weight, texture and quality. The reducing sugars content of all the cultivars were found to Ritu Tandon Punjab Horticultural Postharvest Technology Centre PAU Campus, Ludhiana

be lower than normal cold stored potatoes. The potato stored at 10 ± 2 C and 90-95% RH coupled with CIPC application does not develop sweet taste and therefore are better than cold stored potatoes for culinary purpose. The tubers do not sprout, rot and remain firm and fresh for 6 months. Moreover, with this technology we can save about 40% of electricity cost as compared to conventional storage methods. Farmers, traders and processors can gain a lot from this storage technology. As per reports from UPL Mumbai, about 1.32 lakh MT potato tubers were stored in different district of Punjab with Oorza application during 2017-18.

Ventilation The modern, fully automatic ventilation system controls temperature and circulates air through the potato pile. Air is forced down the main air plenum, outwards and up through the pile by lateral ducts. It is beneficial to have a bypass vent at the end of the main plenum to provide partial recirculation of air to help control condensation in coldest weather. The ventilation system for this storage is designed to provide 8 L.s-1 per tonne. Some storage situations, such as processing potatoes and wet harvest BVC Mahajan Punjab Horticultural Postharvest Technology Centre PAU Campus, Ludhiana

conditions, may require greater air flow. Where this is desired, adjust fan size, controls and duct design as required and according to sound engineering principles. Other storage applications, such as seed potatoes, may require less air than specified in this plan. Ventilation controllers vary in complexity, depending on the number of control strategies. The simplest strategy involves running the fans continuously. The volume of air is manually adjusted through the number of fans operating or by adjusting the speed of the fan(s).

Air Requirements The airflow required to keep potatoes in good condition will vary. Maximum airflow usually is not needed throughout the entire storage season. However, it should be available for rapid cooling and if ‘rots’ begin to develop in the potato pile. Make provisions to reduce the total quantity of airflow for when the maximum is not needed. An interval timer is frequently used to control the amount of total daily airflow. Also, reduced airflow can be accomplished using a two-speed fan or more than one fan per plenum chamber. Unused fans should be covered to prevent backflow, if more than one fan is installed in a plenum chamber.  Mahesh Kumar Punjab Horticultural Postharvest Technology Centre PAU Campus, Ludhiana


energy savings

Energy Loss in AHU

Picture Credit: www.fennerdrives.com

The critical part of the air-conditioning / air washer plant circuit is the final delivery that is diffused through Supply Diffusers inside the AC premises, in terms of supplied cool air’s volume, temperature, static pressure and RH. If the supply air is diffused only, it gives sustained heat transfer and comforts the users in AC premises for long hours...

he critical part of the air conditioning or air washer plant circuit is the final delivery that is diffused through supply diffusers inside the AC premises, in terms of supplied cool air’s volume, temperature, static pressure and RH. If the supply air is diffused only, it gives sustained heat transfer and comforts the users in AC premises for long hours. Now, the air conditioning, air washer OEM and the user industry can target this area to give the above optimized parameters of their input conditioned air and this trivial exercise will give an appreciable savings in the AHU

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electricity consumption. Industry, please concentrate on your slippage from motor to blower now. The slip between the cup & lip in the energy flow is there always, but in some cases we find now, the cup is slipped in between! And slip is reported above 20 % when slip during installation was recorded as only 2 %, few years back. This is happening in all of your AHU (Air Handling Unit) blowers in the air circuit of your air condition / air washer plants. In the blower system, if your belts are actively gripping the pulley, then you are maximizing your belt transmission

efficiency. If your belts are only passively touching the pulley, then your belts & pulley consume more power and less belt transmission efficiency now. The industry must visualize today, the visible loss in their belts and pulleys. If you change your V belt today to Raw Edged Cogged REC belt, this transmits power without loss, compared to the V belt to deliver near the rated Revolutions per Minute (RPM) and hence it gives you more circulation i.e. Air Changes. Simultaneously, if you optimize the ‘motor & load’s pulley to suit to the same output as load RPM, then it is power saving for you. Keep in Mind “Your Belts transmit Power from Motor to Blower only by Friction.” This friction needs to be sustained and as well optimized for better grip of belts at both running ends, for energy saving. If you want to optimize for both powersaving & comfort air-circulation, then reduce the pulley weight and optimize its drive to match to the running load, undernumber the belts from say 3 no V belts to 2 no REC belts (this is subject of many factors) for the same given load. So, focus on belt & pulley change today (and not only the belts only as a routine change), and anticipate more air changes at less power consumption. Kindly monitor and record the ‘before & after’ power readings for the power saving, and RPM change for increase in air circulation. This exercise will indicate you, how much you had lost in belt transmission in each machine, till date.

energy savings Motor drive transmission efficiency Visible Losses seen in belt Losses from motor to load Sr. No. Motor HP Losses % 1 2 8 – 15 2 3 7 – 13 3 4 6 – 12 4 6 5.5 – 10 5 8 5–9 6 10 4.5 – 8.2 7 20 3.5 – 7 8 30 3.2 – 6 9 40 3 – 5.5 10 60 2.8 – 5 11 80 2.5 – 4.5 12 100 2.5 – 4.5 Figure 1: BEE Table indicating the losses happening due to V belts and its variation based on the Motor HP.

Existing Vee Belt Transmission Practices • The motor is coupled to the AHU blower by V belts, either one or in multiples say 2, 3 & more, to suit to the demands. • The V belts are designed for motor at full load rating and 7 out of 10 cases, over belting is designed. • The motor and blower pulley are heavy mass when designed and this adds more to Tare-load consumption of ‘motor + belt + pulley’ upto the load, thus, increasing unproductive load on the motor power. • Because of overweighing-belting, the pulley sizes, belt width and the number of belts go up to increase power demand to motor. • Motor designer of IE 2 and above versions, are reducing the motor cooling fan size so as to reduce the no-load motor power, but blower designer and the user increase the power demand in between by strong heavy belts and multiples of belts, matching heavy pulley at motor & load, and silently ignore the KW demand that has increased to his motor now. • Say for example, 10 HP motor losses vary from 4 to 8 %. So, the loss band is 4 to 8 % implies that the losses are there in V belts and in pulley drives as well. If loss is from belt only, say it is 4

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Details

Motor HP Motor KW Motor Pulley Dia Machine Pulley Dia Actual RPM Actual KW Kw savings with Cog belt drives Savings attained in % Expected Savings / Year Payback in Months

V Belt drive - 4 Drives SPC 75 55 258 425 898 38.27

Cog belt Drive – 3 Drives – XPB 75 55 245 406 890 34.67 3.6

Cog Belt drive – 2 drives – XPB 75 55 245 406 888 33.96 4.31

9.4 192207 1.4

12.4 230115 1.2

Figure 2: Case study of 55 KW centrifugal blower in waste collection centrifugal blower system in a textile mill in South India.

%. If loss is due to Belt +Pulley drive, say it is 8 %, this is what we inferred from our case studies. So, it is not only the change from V belts to Cogged belts, but also the pulley drive needs to be optimized to the running load. The blower was running with 4 V belts before, and the same is swapped with REC belts of less pulley size, but the same speed ratio. The V belts had slippage before, and now cogged belts the slippage is reduced, weight of belt and pulley is reduced to achieve 12 % power savings. Here, the anticipated saving by this exercise was around 5 % belt losses as per the BEE table. This is a typical case study and this power savings will be possible in this centrifugal application only. This saving varies on the load like either like centrifugal / axial flow blower, centrifugal / screw type compressors or pumps etc. This saving varies depending on the nature of rotation in axial / tangential load like blower, pump, and compressor application. The savings will be different for shock loading, pulsating, grinding, agitating, reciprocating working application etc. The AC user industry is in the habit of allowing the belt to tear during running and then only change. Instead of 4 matched belts, the user changes only one or conveniently tries

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to run with balance belts between machine and motor. That too, since the AC AMC is contracted out, this belt issue is silently ignored. Please visit your AHU chamber today, and you will be surprised that this is most likely the neglected area in your day-to-day activities. Loose belts, hotter motor, and dust choked heat exchanger of the AHU. This is one of the factors that contribute the Indoor Air Quality (IAQ), in terms of air changes, air circulation & starvation. Even while changing, the industry views that the belt as OTC commodity and buys from nearby retailer and somehow manage to run the blower, so as to get relieved of the problem.

Optimize AHU Blower’s Output & Achieve Energy Savings • The above AHU name plate image shows this motor shaft output is 7.5 KW / 10 HP & blower gives 6400 CFM @ 65 mmWC. • Confirm with Digital Pascal Meter and Anemo meter, the blower output in CFM and Pascal when measuring the input KW. • Based on case to case basis, when air balancing is done for the inside premises, plan to add VFD to the existing blower to deliver only what is wanted inside i.e. in required Pascal & Cooling India | April 2018| 65

energy savings Blower No. 1 KW 22 KW 22 RPM 1464 RPM 1464 Motor Pulley DA 180 Motor Pulley DA 150 Machine Pulley DIA 270 Machine Pulley DIA 280 Actual M/C RPM (Cal) 976 Actual M/C RPM (Cal) 784 RPM Measured 771 RPM Measured 772 Slippage 21% Slippage 1.50% Belt used B 125 Belt used XPA2 No. of Belts 3 No. of Belts Figure 3: BEE Table indicating the losses happening due to V belts and its variation based on the Motor HP.

CFM for better heat transfer across the Heat Exchanger and as well the required CFM to maintain air balance between the supply & return air volumes by way of air changes. • RPM reduction leads to square of static pressure and in turn reduction in terms of cube of KW power consumed by blower. • So, optimize RPM of blower. Huge energy savings are achieved in electrical as well thermal related by above measures.

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Assess Existing V Belt Losses • Today, with your infra-red Thermal Imager, scan and screen the hundreds of belt driven motors in all your AHU. • Use your non-contact Tachometer to routinely measure your motor and blower speeds and confirm the slippage is within the limits as measured dimensions and calculated

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speed ratio limits. Slippage happens more and silently in these applications. Right from installation and during the change of belts, never ever lever the belts while putting on pulleys. Take care not to elongate the belt right from commissioning and as well take action immediately once you see elongated belt. You focus on the motor & blower drive end bearings, the motor & blower pulleys, and belts end to end. Assuming the ambient cool temperature, the relative temperature increase on belt & pulley drive must not increase above 10*C above the ambient. Any relative temperature deviation shows the nature of abnormality in the alignment. After screening, you can concentrate on the hot spots like belts & pulleys. This is apart from the bearing monitoring on motors.

Figure 5: Cogged Belts and Drives rightly changed for this motor drive system and Energy savings achieved.


Figure 4: AHU / Air Washer parameters old belt loss un-noticed at 21 % slip, and now with REC belts slip reduced to 1.5 % only.

• Measure the motor & blower speeds by non-contact Tachometer, for the normal running load, the dia of motor & blower pulley, calculate the speed ratio and check for slippage losses in each belt transmission. • Also, measure the motor running load, its rated KW, and the motor running frequency in Hz. • Visually check for cracked or worn-out belts, belt tension, alignment and the pulley for heavy wear & tear.

Why Shoud You Replace With Cogged Belt & Pulley Today? • The motor is always not running to the designed full power ratings. • The V belts are not used as matched set and out of say 4 belts, and say 2 out of 4 belts only actively transmit the power. • You have changed your motor starting from Harsh DOL, Star Delta starting to

Figure 6: shows the thermal imaging of worn-out pulley due to belt and alignment issues raises temperature to 89 *C.

Figure 7: AHU motor Heavy belt loosely touching and not gripping the small pulley motor drive pulley.

energy savings

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smooth VFD starting now and so now your belt & pulley also needs to undersized to withstand only slow & soft ramp of VFD starting current. Discuss about the weak transmission points happening in your V belts now with the AHU OEM. The origin of inefficiency due to over design of belt & pulley drive transmission starts from the AHU OEM only. When designed, this REC belt was not focused before and priority towards energy conservation was not there, previously. The efficiency of the mechanical power transmission depends on grip between pulley & belt, further depends on the co-efficient of friction and tensile strength of the belt transmission. This thermal image of belt & pulley will show how much your KW input to motor is unwantedly heating up the belts & pulley drives. You will also find rubber burnt smell and screeching sound when blower is started and these are the signs of wear-out, happening now. This is not safe especially in AHU chamber where they don’t get user’s daily attention. We the Energy Auditors, suggested to the industry till date, to replace with cogged belts only on same pulley so as to instantly achieve energy savings by this swap. After replacement, this reduced the transmission losses by say 3 per cent in terms of RPM and hence increased the power demand from load shaft. The user does not analyze the overall AHU’s performance and air flow improved, but blames that the power demand increased from blower and not satisfied with the exercise done, from V belts to cogged belts. You the industry need to be aware that your pulley (also due to this cyclic belt movement under harsh conditions) needs to be replaced around five years duration, based on the loading nature and thermal imager inputs on pulley. Now, we always suggest after our energy audit to replace belts, and optimize power in their pulley & drive.

• Here, we have to look into the design aspects of what parameter is wanted in each machine either Pascal, RPM or parameters required for the air flow @ given static pressure from this motor & belts system.

Benefits of Cogged Belts & Pulley over V Belts • The cogged belts by design, is having 30 per cent power carrying capacity for the same V belt weight now. • The cogged belts run cooler, run say, 50 per cent more longer hours, and occupy less space in pulley. • The narrow & cogged belts operate higher speed ratios using smaller diameter pulleys. • Hence, this needs the existing pulley to be replaced with say 20 per cent around, less weight pulley. • Kindly study the above 4 fine pointers, this will catalyze you to change to cogged belt immediately, today. • After thermal imaging and measuring the slippage losses, we the energy auditors now suggest to the user, to replace both belts & pulley from V belt to cogged belt now. • Citing the above factors, let us first re-size the pulley, discuss with the belt & machine OEM to achieve the same RPM or the desired RPM after reduced slip, possible now due to this cogged belt. • Belt swap case study on 45 KW blower motor shows motor pulley got reduced from 18 Kg to 10 Kg weight. The Blower pulley got reduced from 55 Kg to 25 Kg weight. This is how power savings space-saving and less weight in transmission yields. • The industry is now looking at ways and means of energy saving in their motor driven systems. You are planning to change your motors from IE 1 to IE 2 and IE 3 motors with VFD compatible versions to improve your motor efficiency levels by few percentage points. But instead of replacing the motor only, you can first focus today on the motor as a system as ‘Motor + Belt & Pulley transmission’ to deliver

the power without any slip in between, upto the blower’s shaft. • We suggest going in for cogged belts due to the additional factors of Correction Power Rating, Speed Ratio, Belt length Correction Factor, and Arc of Contact Correction Factor. These factors aid in optimizing the pulley drive for cogged belts. • When you view your running Blower’s belt transmission, the running belt must look standstill. This is the visual symptom of healthy power transmission from motor to blower by belt. Actively-gripping belts will look like standstill when blower is running. Passively touching belts vibrate more to prompt the losses. • If you see wobulations in your belts, this shows the belt transmission efficiency is losing and energy losses due to slippage, misalignment, poor matching of belts to drive, hotter driveend bearings.

Conclusion Energy auditing involves about optimizing the design parameters to suit to the running conditions and this is a classic case of material conservation in optimizing the ‘pulley & belt change’ for the same given output from the blower shaft at the given running condition, in turn this will lead to power saving too. We the energy auditors have to be the focal point between the blower OEM and the user industry, and maximize machine efficiency and this is win-win situation for all of US. Consult the belt specialist, blower OEM and bring them to your ECON table to achieve energy savings at one stroke. 

S Ashok

BEE Accredited Energy Auditor Coimbatore

K S Subramanian

Specialist Belts & Pulley Drives Coimbatore


environment-friendly

Renewable Energy Approach for Producing Ammonia The new process, published in Nature Catalysis, utilizes a plasma — an ionized gas — in combination with non-noble metal catalysts to generate ammonia at much milder conditions than is possible with Haber-Bosch… esearchers at the University of Notre Dame are developing a renewable energy approach for synthesizing ammonia, an essential component of fertilizers that support the world’s food production needs. The Haber-Bosch process developed in the early 1900s for producing ammonia relies on non-renewable fossil fuels and has limited applications for only large, centralized chemical plants. The new process, published in Nature Catalysis, utilizes a plasma — an ionized gas — in combination with nonnoble metal catalysts to generate ammonia at much milder conditions than is possible with Haber-Bosch. The energy in the plasma excites nitrogen molecules, one of the two components that go into making ammonia, allowing them to react more readily on the catalysts. Because the energy for the reaction comes from the plasma rather than high heat and intense pressure, the process can be carried out at small scale. This makes the new process well-suited for use with intermittent renewable energy sources and for distributed ammonia production. “Plasmas have been considered by many as a way to make ammonia that is not dependent on fossil fuels and had the potential to be applied in a less centralized way,” said William Schneider, H Clifford and Evelyn A Brosey Professor of Engineering, affiliated member of ND Energy and co-author of the study. “The real challenge has been to find the right combination of plasma and catalyst. By combining molecular models with results in the laboratory, we were able to focus in on combinations that had never been considered before.” The research team led by Schneider; David Go, Rooney Family Associate Professor of Engineering in aerospace and mechanical engineering; and Jason Hicks, Associate

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Professor of Chemical and Biomolecular Engineering, discovered that because the nitrogen molecules are activated by the plasma, the requirements on the metal catalysts are less stringent, allowing less expensive materials to be used throughout the process. This approach overcomes fundamental limits on the heat-driven Haber-Bosch process, allowing the reaction to be carried out at Haber-Bosch rates at much milder conditions. “The goal of our work was to develop an alternative approach to making ammonia, but the insights that have come from this collaboration between our research groups can be applied to other difficult chemical processes, such as converting carbon dioxide into a less harmful and more useful product. As we continue studying plasma-ammonia synthesis, we will also consider how else plasma and catalysts could benefit other chemical transformations,” said Hicks. For the study, Prateek Mehta, graduate student in chemical and biomolecular engineering at Notre Dame and lead author, created models to be used by Patrick Barboun, graduate student of Chemical and Biomolecular Engineering at Notre Dame and co-author, and Francisco A. Herrera, graduate student of aerospace and mechanical engineering at Notre Dame and co-author. Together, Barboun and Herrera used the models to conduct lab experiments. Additional contributors include Jongsik Kim, former graduate student at Notre Dame and Senior Research Scientist at the Korea Institute of Science and Technology, and Paul Rumbach, assistant special professional faculty in aerospace and mechanical engineering at Notre Dame. Both Go and Hicks are also affiliated with ND Energy. Resources for this project were provided by Notre Dame’s Center for Research Computing, ND Energy’s Materials Characterization Facility and the Notre Dame Integrated Imaging Facility. 

statistics

Area and Production of Horticulture Crops – All India 2016-17(Final) and 2017-18 (First Adv. Est.)

Area in ‘000 Ha, Production in ‘000 MT

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40 41

Crops Fruits Almond Aonla / Gooseberry Apple Banana Ber Citrus (i) Lime / Lemon (ii) Mandarin (iii) Sweet Orange (Mosambi) (iv) Others Citrus Total (i to iv) Custardapple Grapes Guava Jackfruit Kiwi Litchi Mango Muskmelon Papaya Passion Fruit Peach Pear Picanut Pineapple Plum Pomegranate Sapota Strawberry Walnut Watermelon Others Total Fruits Vegetables Beans Bittergourd Bottlegourd Brinjal Cabbage Capsicum Carrot Cauliflower Cucumber Chillies (Green) Elephant Foot Yam

2016-17 2017-18 (Final) (1st Estimate) Area Production Area Production 12 7 12 8 93 1075 93 1077 305 2265 305 2268 860 30477 857 30201 50 545 49 530 248 410

2364 4438

230 409

2273 4412

191

3209

191

3305

136 985 44 137 260 150 4 93 2212 50 134 13 18 44 1.3 111 24 216 99 0.5 112 91 252 6373

1408 11419 383 2922 3826 1694 12 568 19506 1097 5940 72 106 346 0.2 1861 81 2613 1236 3.8 287 2182 2392 92918

146 976 48 138 261 153 4 92 2259 52 139 13 19 42 1.3 115 23 220 98 0.6 112 92 253 6428

1728 11717 435 2967 3916 1742 12 600 20714 1135 6104 71 117 306 0.3 1988 76 2795 1203 4.3 288 2237 2371 94884

198 95 153 733 395 24 86 454 74 316 29

2012 1030 2529 12510 8807 306 1350 8557 1142 3634 748

197 93 158 729 400 24 88 459 76 311 29

1977 1063 2677 12616 8972 321 1446 8805 1217 3761 555

Sl. No. 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78

Crops

2016-17 (Final) 182 441 507 6003 1306 22427 18 268 530 5345 2179 48605 203 2898

Mushroom Okra/Ladyfinger Onion Parwal/Pointed gourd Peas Potato Radish Pumpkin/Sitaphal/ 74 Kaddu Sweet Potato 128 Tapioca 199 Tomato 797 Others 1558 Total Vegetables 10238 Aromatics and 664 Medicinal Flowers Cut Flowers Loose 306 Total Flowers 306 Honey Plantation Crops Arecanut 455 Cashewnut 978 Cocoa 83 Coconut 2082 Total Plantation 3598 Spices Ajwain 31 Cardamom 85 Chillies (Dried) 840 Cinnamon/Tejpata 3 Celery,Dill & Poppy 36 Clove 2 Coriander 674 Cumin 781 Fenugreek 210 Fennel 91 Garlic 321 Ginger 168 Nutmeg 23 Pepper 132 Vanilla 4 Tamarind 49 Turmeric 222 Total Spices 3671 Total 24851

1664

2017-18 (1st Estimate) 182 432 501 5972 1196 21402 20 325 540 5427 2176 49344 209 3174 76

1709

1460 131 4171 190 20708 801 21557 1584 178172 10172

1465 3627 22337 22059 180684

972

650

1037

693 1699 2392 95

308 308

704 1806 2510 95

723 745 19 16486 17972

455 1041 87 2081 3664

723 817 20 16493 18053

27 31 28 89 2096 844 5 3 35 36 1 2 883 677 493 785 297 211 153 91 1693 323 1070 168 15 23 72 133 0 5 197 49 1056 223 8122 3693 300643 24916

27 29 2106 5 35 1 888 495 299 153 1702 1075 16 73 0 198 1061 8163 305426 Source: PIB


sustainable structure

Green Buildings: End User Perspective Green buildings will aim and contribute towards minimizing the environmental impact. Their performance in the long run will lead to a sustainable construction additionally, delivering several long term benefits to the building owners and the users…

“Green Building is the practice of creating structures and using processes that are environmentally responsible and resource efficient” oing green is a fashionable word today. Very few realize the true essence of green. Whether we want to admit it or not, at some point everyone will have to follow with the green

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movement. The depleting resources and climate change are alarming and we are left with no choice but to adopt the green way of life. The ideal green building would be a

building project that would allow us to safeguard most of the natural environment around the project site, while still being able to produce a building that is going to serve a function. Its construction and

sustainable structure

operation will promote a healthy atmosphere for all involved, and it will not interrupt the land, water, resources and energy in and around the building. This can be the actual definition of a green building. Green buildings will aim and contribute towards minimizing the environmental impact. Their performance in the long run will lead to a sustainable construction additionally delivering several long term benefits to the building owners and the users. They contribute towards lower development costs, lower operating costs, enhanced comforts, healthier indoor environmental quality, and boost durability with much less maintenance costs. The executions and branding for green practices by the developer community has twinkled the awareness light amongst the end users also. Along with commercial property users, it is now noted that residential property buyers are also demanding the green features in the projects. Though the knowledge towards green practices is limited with the buyers, still the thought towards a sustainable home has settled. The buyers have to invest a lot while purchasing a property. It is rather difficult to shell out additional money towards green practices but with the thought of lower maintenance cost for a lifetime studies prove that they are ready to invest up to ` 35/- per square foot over and above the purchase cost. Prime factors that govern a buyer’s decision while purchasing a flat are noted to be location and cost which gets further linked to affordability aspect. It was noted

with various studies that the buyers buying behavior was dictated by the serene and pleasing o u t d o o r environment created with landscaping features and availability of amenities like swimming pool, club house gymnasium etc. followed by security features. Maintenance cost for such amenities is already on the higher side and green features and their maintenance often take a back seat. Major noted constraint amongst the end users is the lack of awareness to the core. With partial knowledge, the society members and the end users may take few decisions in the long run that can hamper the overall concept of going green. The common perception is that maintaining a green construction is probably expensive. Amongst green features, sewage treatment plant scores the highest maintenance issues and often suffers the closure with high cost for running followed by organic waste convertor. The end users are much cost centric than the sustainability aspects, and seem less aware of longer term benefits and savings rather than expenditure. Studies also prove that buyers with lesser affordability are willing to pay higher costs for green features saving energy and water when compared to other luxurious options. Majority buyers was willing to pay for the landscape elements along with the investment range of ` 3/- to ` 5/- per sq. ft with 35% of the sample going further up to ` 7/- and higher. 45% of the buyers were willing to invest higher than ` 5 to ` 10/- for energy saving parameters and passive envelope. Green buildings and green appliances are viewed as a luxury market. However, there is growing awareness of the benefits of green building and demand is growing slowly, especially, in commercial spaces. There is a need for large-scale awareness

and capacity-building programmes. Benefits for the end users are often noted only with tangible aspects. The comfort, health and well being aspects, community living concepts often get neglected with green building notions. To bridge this gap, awareness enhancement amongst several target groups can prove to be an essential step to promote green buildings. Sharing of technical information in terms of brochures, posters and other information material may prove useful to certain extent. An appraisal of energy efficiency goal and relevant details should be shared with the stakeholders and communicated to relevant intended groups for successful policy making. The goal should be well defined, achievable, reasonable, and convey the benefits from a long and short term vision. The end users need to be convinced about the potential benefits so that they are more likely to support green building development. Green buildings should not be marketed only on the basis of technical aspects, water savings, and energy efficiency or cost saving aspects, but as a comprehensive approach improving the overall quality of life, human health with buildings, including architectural quality, aesthetics, housing comfort and social prestige. From developer’s side, to raise alertness and stimulate enthusiasm and the need for action, a broad public campaign may also prove beneficial. Such campaigns can be promoted with brand ambassadors and other marketing strategies. The real estate and housing sectors and its associations, along with the statutory bodies could join for promotional efforts and operate on a collective platform. With the apt awareness, at every individual project level, a strong team with clear vision can drive the entire project towards a long term beneficial green building with long term benefits. 

Anshul Pranay Gujarathi

LEED-USGBC Accredited Professional, GRIHA Trainer & Evaluator and an IGBC AP, Founder, Eco solutions


product profile Thermal Imaging Camera for Electrical/Mechanical Applications he entry-level E53 Advanced Thermal Imaging Cameras offer the superior resolution and range performance needed to quickly identify hot spots and discover potential points of failure in electrical distribution and mechanical systems. With 43,200 pixels resolution and a more vibrant LCD screen than any other pistol-

grip camera, the E53 makes it easier than ever to diagnose problems—even at a distance. Avoid costly shutdowns and lost production time through regular predictive maintenance routines with these rugged, intuitive cameras and improve plant reliability & safety and make your work easier.

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• Temperature range is -20°C to 120°C with FOV of 24° × 18° & 5MP digital camera. • Detect temperature differences as small as