Existing system
- Chillers
- 2 YORK units selected for replacement; COP approximately 3.0
- Chilled-water pumps
- No VFD
- Annual plant electricity
- Approximately 2,552,000 kWh/year
Manufacturing retrofit
BAT – Vinataba
A turnkey chiller plant modernization delivered while the Dong Nai factory remained in production.
- Client
- BAT – Vinataba
- Location
- Dong Nai, Vietnam
- Period
- 18 Oct – 20 Dec 2015
- Capacity
- 520 RT
- Scope
- Turnkey plant retrofit
Results
The outcomes in context.
- Energy saving per day
- ≈3,100 kWh
- Energy saving per year
- ≈1,131,500 kWh
- Chiller energy saving
- ≈50%
Project story
From the operating brief to the handover.
The challenge
Understand what needed to change.
The plant’s existing YORK chillers operated at approximately COP 3.0. Chilled-water pumps had no VFD, and the reference records approximately 2,552,000 kWh/year of chiller plant electricity use. APC had to replace two YORK chillers without interrupting production.
Our solution
Coordinate the plant as one system.
APC supplied a 520 RT SMARDT oil-free magnetic-bearing chiller with four compressors, iCPECS control of the chilled-water pumps, condenser-water pumps and cooling towers, pump VFDs, piping and field instruments.
The result
Review the documented outcome.
The reference reports approximately 3,100 kWh/day and 1,131,500 kWh/year of energy savings, with roughly 50% chiller savings against the previous system. Maintenance costs were reduced and selected removed components were retained as spares.
Before & after
What changed in the plant.
APC solution
- Chiller
- SMARDT 520 RT, 4 compressors, oil-free magnetic bearings
- Pumps and towers
- iCPECS coordination; VFD on pumps
- Annual energy saving
- Approximately 1,131,500 kWh/year
Scope of supply
A clear delivery scope.
- Site survey and engineering consultancy
- Custom design for energy optimization
- Proposal and energy-saving estimate
- Installation and supervision
- Project management
- Testing, commissioning and performance verification
- Operator training and documentation
- Yearly maintenance, spare parts and troubleshooting service
Work performed
18 Oct – 20 Dec 2015
- 01Remove the two selected YORK chillers within a 24-hour window
- 02Lift the SMARDT unit into position using a 50-ton crane
- 03Connect chiller power and the iCPECS control panel
- 04Install pump VFDs, piping and field instruments
- 05Commission and verify the operating performance
- 06Train chiller and iCPECS operators
Key equipment
The equipment behind the scope.
SMARDT oil-free water-cooled chiller
520 RT, approximately 1,828 kWr; 4 compressors
View equipmentiCPECS
Chilled-water pumps, condenser-water pumps and cooling towers
Pump VFDs and field instruments
Piping, power connections and measurement points
Commissioning data
Recorded under real test conditions.
The following part-load ranges describe this installation’s commissioning tests. They are not rated performance guarantees for other projects.
| Load | Capacity (kWr) | Input (kWe) | COP |
|---|---|---|---|
| 59–63% load | 920–995 | 120–133 | 7.4–8.0 |
| 43–45% load | 680–717 | 74–79 | 8.7–9.6 |
Gallery
Inside the project.
Project photographs published by APC. Read the original reference for the installation scope and operating context.
Enlarge photograph
Enlarge photograph
Enlarge photograph
Enlarge photograph
Enlarge photograph
Enlarge photograph
Enlarge photograph
Enlarge photographReferences & downloads
Read the original project material.
Turnkey project
