CASE15 · Manufacturing · CDA and chiller utilities
Building a metering-led utility optimization plan for electronic components
Annual CDA and cooling records support a staged proposal: an initial compressor improvement followed by additional utility optimization. Sensor consistency is a prerequisite for credible performance comparisons.
01 · CASE ANALYSIS
Operating challenge
CDA and chillers together used approximately 80.03 GWh/year. Flow and temperature measurement quality needed to be established before calculating equipment-level savings.
The proposal reviewed demand patterns, air discharge/venting, unit controls, chiller outlet temperatures, staging, pumps, cooling towers and line-level cooling balance.
02 · CASE ANALYSIS
Data and reported performance
CDA used approximately 42.36 GWh/year to produce 245.47 million m³, giving annual UPI around 0.173 kWh/m³. Average compressor staging was 8.3 units, ranging from 7 to 10; average seasonal airflow was approximately 28,000 m³/h.
Three cooling circuits used approximately 37.67 GWh/year. Their reported UPI values were 0.667/0.622/0.706 kWh/RT, loads 70%/70%/52% and average unit counts 4.2/1.9/1.3.
| Boundary | Electricity / output | Performance |
|---|---|---|
| CDA | 42.36 GWh; 245.47 million m³ | 0.173 kWh/m³ |
| Cooling | 37.67 GWh | Three major circuits |
| Combined | 80.03 GWh | Annual electricity, not savings |
03 · CASE ANALYSIS
Staged improvement proposal
The first compressor step targets 5% against the late-December 2017 average. The monetized second step targets an additional 3% after that initial compressor improvement and an additional 3% in the cooling system.
Install missing equipment flow meters, calibrate existing sensors, implement monitoring and operating scenarios, then train operators and perform data-based optimization. The proposed project lasts about twelve months.
04 · CASE ANALYSIS
Expected economics and M&V
The source estimates approximately KRW 92 million/year from additional compressor optimization and KRW 87 million/year from cooling, rounded to approximately KRW 180 million/year combined.
The proposal states approximately KRW 300 million for system installation/consulting and approximately two years payback on its investment assumptions, including sensor installation. Savings must be verified using calibrated energy, flow, cooling load, pressure, weather and production records.
| Step | Reference | Expected effect |
|---|---|---|
| Initial CDA optimization | Late-December 2017 mean power | 5% target |
| Additional CDA optimization | Approximately 102 MWh/day × 95% | Additional 3%; KRW 92 million/year |
| Additional cooling optimization | Approximately 93 MWh/day | Additional 3%; KRW 87 million/year |
| Combined additional benefit | Proposal reference approximately 195 MWh/day | Approximately KRW 180 million/year |
05 · CASE ANALYSIS
Engineering lesson
Sequential targets must be described in sequence. The initial compressor 5% and later utility 3% are not an additive verified 8% site saving.
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