MVML Chakan Pune HVAC Project

Facility :

MVML, Chakan, Pune

Type :

Vehicle Manufacturing Facility (Paint Shop – J Block)

System Capacity

300 TR

Cooling System :

Water-cooled chiller plant with primary variable pumping system

MVML is a high-end vehicle manufacturing facility spread across 700 acres in the Chakan Industrial Area, operational for over a decade. The paint shop block (J Block) was designed with a 300 TR chiller plant, but during an audit, the system was found to be performing at poor efficiency.

Audit Findings (Observations)

During the chiller plant audit, Aerosys identified multiple design and operational inefficiencies:

Poor water quality → scaling on condenser side → higher condenser approach & reduced chiller performance
Oversized primary and condenser pumps → consuming excess power
No VFDs on ancillary equipment → pumps ran at full speed regardless of load
Cooling tower performance is satisfactory, but poor maintenance has increased the cooling tower approach
Excess water flow observed at the chiller condenser and evaporator sides, beyond design requirements

These inefficiencies resulted in wasted energy and higher operational costs

Solutions Implemented

Chiller Maintenance

- Descaling condenser and evaporator to restore heat transfer efficiency

Cooling Tower Optimization

- Improved water quality management as per manufacturer guidelines
- Regular maintenance to lower the cooling tower approach

Ancillary Equipment Optimization

- Installed control panel with VFDs and field sensors to optimize pump operations based on load

System Balancing

- Performed chilled water and condenser water balancing to match design parameters

Impact

Aerosys delivered significant improvements:

14% energy savings (372 kWh/day, proved 410 kWh/day)
Annual cost savings of ₹11.07 lakh
ROI achieved in just 7 months
Enhanced chiller efficiency, reliability, and system stability
Reduced carbon footprint with

Key Audit Results

System Capacity: 300 TR
Estimated Savings: 372 kWh/day
Proved Savings: 410 kWh/day
Yearly Savings: ₹11,07,000
ROI: 7 months
Carbon Credits Earned: 125