Facility :
City Centre Mall (CCM), Nashik
Type :
Commercial Mall Facility
Owner
Sarda Group
Built-up Area :
8 lakh sq. ft.
Cooling System :
Chiller plant with 1300 TR capacity, primary constant and secondary variable pumping system, and thermal energy storage.
The mall houses retail stores, cinemas, banquet halls, a gaming zone, and a food court, requiring a robust air-conditioning system. However, the facility faced operational challenges including:
- Frequent hot and cold pockets
- High energy consumption
- Poor chiller plant performance
Audit Findings (Observations)
During the chiller plant audit, Aerosys identified multiple design and operational inefficiencies:
- Poor chiller maintenance → low efficiency
- Primary pump head insufficient → negative pressure in chilled water line
- Condenser pump capacity inadequate → negative static pressure
- Undersized condenser inlet → high velocity, improper water flow distribution
- AHU issues → installed with 3-way control valves, variable secondary pumps causing uneven temperature control and power loss
- Thermal energy storage tanks → instead of saving energy, they increased power consumption due to the minus-temperature operation and additional circulation pumping
These inefficiencies led to excessive energy consumption and O&M costs, with the plant running well below its design efficiency.
Solutions Implemented
Chiller Maintenance
- Descaling the evaporator and condenser
- Replacing cooling tower fills
Operational Optimization
- Removed thermal storage tanks, PHE, and associated pumps
- Replaced 3-way AHU valves with 2-way valves
- Performed AHU water balancing
System Redesign
-Increased condenser inlet pipe size from 4” to 6”
-Balanced chilled water and condenser water systems
Control System Tuning
- Used existing field sensors and control systems for part load efficiency improvement
- Resolved low ΔT syndrome
Impact
By eliminating design flaws and improving plant efficiency, Aerosys delivered:
- 38% energy savings(≈1950 kWh/day)
- Proved savings of 2100 kWh/day
- Annual cost savings of ₹86.9 lakh
- ROI achieved in just 1.2 months
- Reduced O&M costs and improved plant reliability
- Increased condenser inlet pipe size from 4” to 6”
- Balanced chilled water and condenser water systems
Key Audit Results
- System Capacity: 1300 TR
- Estimated Savings: 1950 kWh/day
- Proved Savings: 2100 kWh/day
- Yearly Savings: ₹86,94,000
- ROI: 1.2 months
- Carbon Credits Earned: 714
Chiller Plant kW/TR
- Design: 0.98 kW/TR
- Tested: 1.68 kW/TR
Chiller kW/TR
- Design: 0.87 kW/TR
- Tested: 1.26 kW/TR
