Menara Maybank - Preliminary Energy Walk Thru Audit by Tatasolusi Pratama

Preliminary Energy Appraisal Report
For
Menara
Prepared By:
Tatasolusi Pratama Sdn Bhd

(A wholly owned subsidiary of Solutions Pte Ltd)
26 Ayer Rajah Crescent #05-01/02 Singapore 139944 Tel: +65 6735 5640 Fax: +65 6735 5420
E-mail: info@boss.com.sg
This document is the property of Tatasolusi Pratama Sdn Bhd. No exploitation or transfer of any
information obtained herein is permitted in the absence of an agreement with Tatasolusi Pratama. Neither
this document nor any such information may be released without the written consent of Tatasolusi
Pratama Sdn Bhd
Confidential Page 1 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Acknowledgement
Tatasolusi Pratama Sdn Bhd would like to express sincere appreciation for all the
support, help, full corporation and contributions from the staff of Maybank, during the 2
days Walk Through Audit at Menara Maybank.

Table of Contents
Executive Summary ........................................................................................................................ 4
1. Overview ..................................................................................................................................... 6
1.1 The Purpose of this Report.................................................................................................... 6
1.2 Introduction of Tatasolusi Pratama ....................................................................................... 6
1.3 Building Descriptions of Menara Maybank.......................................................................... 6
2. Electrical Consumption in Menara Maybank ............................................................................. 7
3. Evaluation of Air-Conditioning System Efficiency.................................................................. 11
3.1 Description of Air-Conditioning System in Menara Maybank........................................... 11
3.2 Water-Cooled Chilled Water System.................................................................................. 11
3.2.1 Water-Cooled Centrifugal Chillers .............................................................................. 11
3.2.2 Chilled Water Pumps and Condenser Water Pumps.................................................... 13
3.2.3 Cooling Towers............................................................................................................ 15
3.2 Water Cooled Package Units (WCPU) ......................................................................... 16
3.4 Split Type Air-Conditioning Units ..................................................................................... 17
3.5 Methodology of Estimating System Efficiency for Air-Conditioning Systems ................. 17
3.6 Summary of Estimated kW/Ton of Air-Conditioning System Efficiencies........................ 24
4. Immediate Measures for HVAC System Optimization ............................................................ 25
4.1 Immediate Measures ........................................................................................................... 25
4.1.1 Air Handling Units........................................................................................................... 25
4.1.2 Water Cooled Package Unit at 4-6 and 45-52 system. .................................................... 25
4.1.3 Chilled Water System at Basement 2 and 35th Floor ....................................................... 26
4.2 Fresh Air Supply ................................................................................................................. 27
5. HVAC Systems Retrofit Proposal............................................................................................. 28
5.1 Benefits of Detailed Energy Audit Exercise ....................................................................... 29
5.2 Detailed Energy Audit ........................................................................................................ 29
5.3 Detailed Energy Audit Retrofit Approach vs Conventional Retrofit Approach ................. 31
5.4 Retrofit Plan ........................................................................................................................ 32
6. Energy Economic Analysis ....................................................................................................... 34
7. Conclusion ................................................................................................................................ 37

Executive Summary
Tatasolusi Pratama Sdn Bhd has conducted an Energy Walk Through Audit (WTA) at Menara Maybank
in May, 2006.
The average electricity bill per month in 2004 and 2005 of the Menara Maybank was RM 560,000/month.
We estimated in 2006, under the new tariff rate of TNB, the monthly electrical cost will rise to RM 583,000
or annual electrical cost of RM 7 mil. Upon analyzing the data collected during the WTA, electricity bill per
month for the entire Air-Conditioning and Mechanical Ventilation (ACMV) system is about RM 350,000
per month, which accounts for 60% of monthly electrical bill.
kWh Consumption by Usage
Lift & Escalator Others

5% 5%
Domestic Water
2%
Equipment
8%
Chiller Plant
40%
Lighting
18%
Ventilation
3%
AHUs
ACSUs
4%
3% WCPUs
12%
Thus, Tatasolusi recommends Menara Maybank to implement energy efficiency optimization program
(EEOP) on its 18 years old ACMV system in order to make substantial energy cost saving from its
electrical cost.
EEOP includes
i. performing a detailed energy audit on the existing ACMV system to measure the baseline
efficiency and cooling load profile,

ii. retrofitting the existing ACMV system with equipment of higher efficiency available commercially
in today’s technology
iii. performing a post-retrofit energy audit to measure and verify the efficiency improvement and
energy savings
iv. incorporating a energy supervisory system to ensure efficiency sustainability of the new
system.
The main objective of a detailed energy audit is to reaffirm the energy efficiency and usage by using
highly accurate scientific tools and instrumentation. The detailed energy audit shall examine, data log and
accurately quantify the magnitude of potential energy demand reduction in the ACMV system.
Step i) is the first crucial step to ensure successful implementation of energy saving initiatives and
sustainability of energy efficiency in Menara Maybank without compromising the building comfort. Steps ii)
to iv) are long term measures to improve and sustain energy efficiency in Menera Maybank for another 20
years.
The estimated capital investment to improve energy efficiency and building comfort may cost up to RM
RM 15 mil, with payback ranging from 10 to 14.3 years, depending on the proposals and approach
chosen by Maybank.
Tatasolusi Pratama Sdn Bhd strongly recommends Maybank implement the EEOP on a performance
based energy saving guaranteed contract. Performance based contract is to ensure the system
efficiency and energy saving are achieved and sustained over an agreed period of time between
Maybank and the appointed Turnkey Contractor with Tatasolusi being engaged as the energy consultant
to provide detailed energy audit, design, project management and analysis to realize and verify the
actual energy saving achieved.

1. Overview
1.1 The Purpose of this Report
The purpose of this exercise is to study the energy consumption with the objectives to estimate baseline
efficiency of existing building systems, benchmark the baseline efficiency against the original design
efficiency and the state of the art efficiency with available technology in today’s marketplace, and identify
energy saving opportunities through system optimization and replacement.
1.2 Introduction of Tatasolusi Pratama
Tatasolusi Pratama Sdn Bhd is a wholly owned subsidiary of Super Solutions Ptd Ltd. SuperSolutions
Pte Ltd is Asia’s leading provider of innovative world class services and total solutions to help building
owners improve energy efficiency and building comfort.
In the past 6 years, we have won numerous awards in the ASEAN region for energy efficiency projects
we have completed for a wide range of clients.
We guarantee energy efficiency for building owners, resulting in significant energy savings that help
owners improve their bottom line in the midst of rising electrical tariffs around the world.
Our clients have achieved energy savings of 20% to 70% with our solutions.
1.3 Building Descriptions of Menara Maybank
Menara Maybank was completed in 1988. The building consists of 52 storeys and has approximately
1,000,000 sq ft of total gross floor area.. The height of the building is 725 ft and the building splits into
three phases according to the following.
• Phase I – Basement 3 to Level 3
• Phase II – Level 3 to Level 13
• Phase III – Level 13 to Level 52
There are main building car park from basement 1 to 3 and also annex car park. Spaces in 15 floors of
the building are tenanted out to legal firms and property companies. There is a kitchen on L49 for banquet
hall and an internal food court at the Level 1.
The mechanical floors are B2, L13, L35 and L45. The operating hours of the building are from 7:00AM to
5:45 PM.

2. Electrical Consumption in Menara Maybank
The last two years’ electricity bills from December 2003 to April 2006 for the overall Menara Maybank are
summarized in Table 2.1 and Figure 2.1.
Table 2.1 – Monthly Electrical consumption from Dec 2003 to April 2006
Electrical Maximum Electrical Demand Electrical Demand Total

Year-
Usage Demand Tariff Rate Cost Charge Electrical
Month
(kWh) (kW) (RM/kWh) (RM/kW) (RM) (RM) Bill (RM)
Dec-05 2,256,884 5,856 0.208 17.300 469,432 101,308 570,740

Nov-05 1,913,892 5,913 0.208 17.300 398,090 102,288 500,377
Oct-05 1,099,160 3,610 0.208 17.300 228,625 62,453 291,078
Sep-05 2,276,192 6,131 0.208 17.300 473,448 106,071 579,519
Aug-05 2,415,562 6,227 0.208 17.300 502,437 107,727 610,164
Jul-05 2,361,084 6,111 0.208 17.300 491,105 105,715 596,820
May-05 2,277,564 6,169 0.208 17.300 473,733 106,728 580,461
Apr-05 2,520,269 6,078 0.208 17.300 524,216 105,149 629,364
Mar-05 2,047,733 6,068 0.208 17.300 425,928 104,978 530,906
Feb-05 2,160,000 6,030 0.208 17.300 449,280 104,319 553,599
Jan-05 2,384,000 6,030 0.208 17.300 495,872 104,319 600,191
Dec-04 2,190,000 6,080 0.208 17.300 455,520 105,184 560,704
Nov-04 2,350,000 6,040 0.208 17.300 488,800 104,492 593,292
Sep-04 2,346,000 6,120 0.208 17.300 487,968 105,876 593,844
Aug-04 2,192,000 6,140 0.208 17.300 455,936 106,222 562,158
Jul-04 2,464,000 5,960 0.208 17.300 512,512 103,108 615,620
Jun-04 2,232,000 6,210 0.208 17.300 464,256 107,433 571,689
Jun-04 2,046,000 6,250 0.208 17.300 425,568 108,125 533,693
May-04 2,406,000 7,560 0.208 17.300 500,448 130,794 631,242
Apr-04 2,486,000 6,160 0.208 17.300 517,088 106,568 623,656
Mar-04 2,008,000 6,070 0.208 17.300 417,664 105,011 522,675
Feb-04 2,158,000 6,110 0.208 17.300 448,864 105,703 554,567
Jan-04 2,352,000 5,860 0.208 17.300 489,216 101,378 590,594
The above table and figure show the trend data of the electrical bill at Menara Maybank and the highest
monthly electrical bill was RM 631,242 in April 2004, and the lowest was RM 291,078 in October 2005.
The average monthly electrical bill for period 2004 to 2005 is RM 565,085.

By overlaying the 2005 monthly electric cost against 2004 as in figure 2.2, we found that there was a dip
of electric cost in 2005 Oct against 2004 Oct. This could be due to the monthly bills preceding to 2005 Oct
are “Bil Anggaran” or “Estimated Bills” from TNB, and TNB made an adjustment of billing in the month of
October.
Annual electric cost in 2005 was about 5% lower than 2004, RM 6.54 mil in 2005 vs RM 6.95 mil in 2004.
This could be contributed by the drop in electric usage as Maybank adopted the 5-day week working
system in 2005, as compared to 5-1/2-day week in 2004.
Figure 2.1 Monthly Electric Cost in 2005 vs 2004
Monthly Electric Cost, 2005 vs 2004
700,000
600,000
500,000
Monthly Electric Cost (RM)
400,000
2005
2004
300,000
200,000
100,000
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
The breakdown of monthly kWh consumption by building systems is shown in Figure 2.3. The values are
based on chilled water system operating hours of 10.5 hours, WCPU operating hours of 12 hours and
split units operating hours of 11 hours. The figure shows the major consumers of the electricity in Menara
Maybank.

kWh Consumption by Usage
Lift & Escalator Others

5% 5%
Domestic Water
2%
Equipment
8%
Chiller Plant
40%
Lighting
18%
Ventilation
3%
AHUs
ACSUs
4%
3% WCPUs
12%
Figure 2.3 Breakdown of monthly kWh consumption by usage
From the breakdown of kWh consumption, the chilled water system which comprises chiller plants and
chilled water AHUs and FCUs consumes about 44% of the total kWh consumption. By summing up the
kWh consumption of chilled water system, WCPUs and ACSUs, it shows that the HVAC system
consumes about 60% of the total kWh consumption.
Therefore, putting our focus on re-designing and resizing of the HVAC system through optimization and
major equipment replacement, it will deliver immense benefit of energy cost saving. At the same time, the
desired comfort conditions and indoor air quality (IAQ) can be maintained at all time in Menara Maybank.
2
In terms of annual kWh consumption, Menara Maybank consumed 278 kWh/m /year and 293
2
kWh/m /year in 2005 and 2004 respectively.
Refer to figure 2.4, kWh consumption at Menara Maybank is clearly above industry average for
2
commercial buildings at 240 kWh/m /year. kWh consumption at Menara Maybank is also way above the
newly constructed building, for example, Securities Commission headquarters at Bukit Kiara which won
2
the ASEAN Energy Award in 2001 was claiming to consume only 120 kWh/m /year.

The kWh consumption at Securities Commission HQ was achieved by optimizing the building Overall
Thermal Transfer Value (OTTV) to 35 W/m2 as compared to 45 W/m2 at conventional glass buildings
through advance architectural design.
For an existing 28-year old building like Menara Maybank, we have little chance to improve the OTTV as
this involves major change in architectural design. However, we can still improve the system efficiency of
2
the HVAC system (kW/Ton) and lighting system (W/Lumens) to reduce annual 120 kWh/m /year to below
industry average.
Figure 2.4 Insdustry benchmark for energy consumption in commercial buildings within South East Asia region
Industrial Average
kWh/m2/Year for Commercial Building
240 kWh/m2/Year
(South East Asia)
0 50 100 150 200 250 300

Securities Commision
ASEAN Energy Award Winner 2001 Menara Maybank (2005)
1,000,000 ft 2 1,000,000 ft 2
120 kWh/m2/Year 278 kWh/m2/Year

3. Evaluation of Air-Conditioning System Efficiency
3.1 Description of Air-Conditioning System in Menara Maybank
There are four types of air-conditioning system in the building listed as below:
3.1.1 Water-cooled chilled water system – chiller plants located at B2 and level 35, 89 units of AHUs
th th th
serving level G to 12 and level 13 to 44 , and 21 units of FCUs serving some of the lift lobbies.
th
3.1.2 Water-Cooled Packaged Units (WCPU) - 33 units of WCPU serving selected areas at level 5 to
th th th
7 , and executive floors from level 46 to 50 .
3.1.3 Air-cooled chilled water system – a small air-cooled chiller with remote air-cooled condenser is
installed at level 52.
3.1.4 Air-Cooled Aplit Units (ACSU) -. about 60 units ACSUs scattered all over the buildings to serve
the server rooms which require 24-hour air-conditioning.
3.2 Water-Cooled Chilled Water System

3.2.1 Water-Cooled Centrifugal Chillers
The existing chiller plant room at basement 2 is equipped with a total numbers of 4 Carrier centrifugal
chillers consisting of 3 nos. of 450RT chillers and one 200RT chiller.
Figure 3.1 One of the chillers at basement 2

During the WTA, 450 RT Chiller #2 & Chiller #3 are running as the following data.
Table 3.1 Chillers operating data as per WTA (Basement 2)
Chiller B2-2 (450 RT) Chiller B2-3 (450RT)

kW Running 244 237
Ampere Measurement 401 392
Chilled Water Supply o o
8.3 C 9.2 C
Temperature
Chilled Water Return o o
12.9 C 13.1 C
Temperature
There are three Carrier 700 RT centrifugal chillers and one 200 RT centrifugal chiller installed in the
chiller plant room at Level 35.
Figure 3.2 Chillers located at Level 35
The Chillers at the Level 35 are running at the following conditions.
Table 3.2 Chillers operating data as per WTA (Level 35)
Chiller 35-3 (700 RT) Chiller 35-4 (700RT)

kW Running 513 537
Ampere Measurement 100 104
Chilled Water Supply o o
9.6 C 10.4 C
Temperature
Chilled Water Return o o
14.8 C 14.7 C
Temperature

3.2.2 Chilled Water Pumps and Condenser Water Pumps
There are 5 chilled water pumps and 3 secondary chilled water pumps at the basement 2 and six chilled
water pumps and 4 secondary chilled water pumps at the Level 35.
Figure 3.3 Chilled water pumps (a) and Secondary chilled water pumps (b) from Level 35
(a)
(b)

The chilled water pumps at the level 35 are running accounting to the following data during WTA.
Table 3.3 Chilled water pumps (Level 35) operating data as per WTA
CHWP 35-3 CHWP 35-4 SCHWP 35-1 SCHWP 35-2 SCHWP 35-3
Ampere
26.6 26.9 69.3 72.0 68.8
Measurement
Rated Motor
18.5 18.5 45 45 45
kW
Table 3.4 Chilled water pumps (Basement 2) operating data as per WTA
CHWP B2-2 CHWP B2-3 SCHWP B2-1 SCHWP 3B2-2
Ampere
11.7 12.0 75.0 80.0
Measurement
Rated Motor
11 11 45 45
kW
There are 5 condenser water pumps in the plant room of basement 2 and six condenser water pumps in
the plant room of level 35. The running data that collected during WTA will be shown in table 3.5.
Table 3.5 Condenser water pumps operating data

CWP 35-3 CWP 35-4 CWP B2-3 CWP B2-4
Ampere
101.0 92.0 60.5 60.5
Measurement
Rated Motor
75 75 37 37
kW

3.2.3 Cooling Towers
Figure 3.4 Cooling Towers from Level 52 (a) and Ground Level (b)
(a)
(b)

Cooling towers at Menara Maybank are placed at ground level as well as at level 52 those are serving as
showing in Table 3.6.
Table 3.6 List of Cooling Towers
Cooling Tower Floor Serving Running Amp

CTG-1 External Ground CH B2-2
CTG-2 External Ground CH B2-3 41
CTG-3 External Ground CH B2-4 28
CTG-4 External Ground 6 No. of Computer A/C Unit from L6
CTG-4S External Ground 6 No. of Computer A/C Unit from L6
CTG-5A (closed circuit) External Ground WCPU System 1(Ground)
CTG-5B (closed circuit) External Ground WCPU System 1(Ground)
CTG-6 (closed circuit) External Ground WCPU System 2(L6+L7)
CT 52-1 52 CH 35-2
CT 52-2 52 CH 35-2
CT 52-3 52 CH 35-3 43
CT 52-4 52 CH 35-4 31
CT 52-5 52 WCPU System 3 (L45-L50) 29
CT 52-6A 52 Computer Wet Stack System
CT 52-7B 52 Computer Wet Stack System
3.2 Water Cooled Package Units (WCPU)
Menara Maybank building has total three water cooled package unit systems using Carrier WCPUs
controlled by Honeywell controls to serve different levels.
The locations of WCPU systems are as following.
• WCPU System 1 - Ground Level
• WCPU System 2 - Level 6 & 7
• WCPU System 3 – Level 45-50
Figure 3.5 One of the WCPUs from Menara

Maybank

Total 12 floors of the building, about 219,600 sq ft of floor area are served by WCPU. Operating hours of
the WCPU is 12 hours per day.
3.4 Split Type Air-Conditioning Units

There are about 60 split air-conditioning units to serve the server rooms. They are running 24 hours per
day and total cooling capacity of split units is 100 tons.
3.5 Methodology of Estimating System Efficiency for Air-Conditioning

Systems
We measure the efficiency of the chilled water system in term of kW/ton. kW/ton represent the amount of
kW (electrical consumption) to produce one ton of the cooling load. Hence, smaller kW/Ton means better
efficiency of the system.
Power in kW required to run the system can be easily obtained by recording the running amps, voltage
and power factor readings from the electrical panels installed at the chiller plants.
The challenge is to estimate the cooling loads in Tons at the point of walk thru audit measurements.
Cooling Load in tons can be estimated from either one of the followings:
Ground Floor Area (GFA)
Differential Temperature (∆T)
Running Ampere (Amp)
We can safely assume one ton of the cooling load is needed to serve every 500 sq ft of the floor area,
which is typically true for most office buildings in tropical region. From this we can estimate the cooling
load.
Another way is to measure the differential temperature (∆T) of the chilled water across the chillers. The
o
ideal differential temperature or delta T (∆T) across the chillers is around 5.5 C at full chiller capacity.
Thus, the loading percentage of any given chiller at site can be estimated from the measured differential
temperature.
From the other hand if we measure the running ampere of a chiller, we can also estimate the cooling load
by comparing the running ampere against the full load ampere of the chiller.
Comparing the cooling loads estimated from the above three methods will help us to determine the
prevalent cooling loads during the walk thru audit, thus, determining the existing system kW/Ton.
3.5.1 Estimated kW/Ton of Chiller Plant at B2
During the walk thru audit, two units of 450-ton Carrier 19DK chillers were running in the B2 chiller plant.
The chilled water was circulated through the chillers via primary pumps, whereas the chilled water was
distributed to the AHUs via secondary pumps. Condenser water pumps was used to circulate condenser
water to the cooling towers located at lower ground level, at an adjacent area external to the building, to
reject heat to the ambient atmosphere.
The chiller plant efficiency is estimated at 1.05 kW/Ton excluding the airside or AHU kW. There is
tremendous potential for efficiency improvement as achievable state of the art chiller plant efficiency is
around 0.68 kW/Ton (exclude airside kW/Ton). The state of the art efficiency can only be achieved
through chiller plant replacement with chillers, associated system accessories and controls of higher
efficiency.
Table 3.7 B2 Chiller Plant kW/Ton Estimation

Rated Input Input Input Running
No. Item Capacity % Load Amp Voltage PF kW Tonnage
1 Chiller B2-1 450 ton 0% 0 415 0.85 0.00 0
2 Chiller B2-2 450 ton 100% 401 415 0.85 245 348.3
3 Chiller B2-3 450 ton 100% 392 415 0.85 240 332
4 Chiller B2-4 200 ton 0% 0 415 0.85 0.00 0
5 P-CHWP B2-1 11 kW 0% 0 415 0.87 0.00
6 P-CHWP B2-2 11 kW 100% 12 415 0.87 7.32
7 P-CHWP B2-3 11 kW 100% 12 415 0.87 7.50
8 P-CHWP B2-4 11 kW 0% 0 415 0.87 0.00
9 S-CHWP B2-1 45 kW 100% 75 415 0.87 46.90
10 S-CHWP B2-2 45 kW 100% 80 415 0.87 50.03
11 S-CHWP B2-3 45 kW 0% 0 415 0.87 0.00
12 S-CHWP B2-4 45 kW 0% 0 415 0.87 0.00
13 CWP B2-1 37 kW 0% 0 415 0.87 0.00
14 CWP B2-2 37 kW 100% 61 415 0.87 37.83
15 CWP B2-3 37 kW 100% 61 415 0.87 37.83
16 CWP B2-4 18.5 kW 0% 0 415 0.87 0.00
17 CT B2-1 kW 100% 0 415 0.87 0.00
18 CT B2-2 kW 100% 41 415 0.87 25.64
19 CT B2-3 kW 100% 28 415 0.87 17.51
20 CT B2-4 kW 0% 0 415 0.87 0.00
Total kW 715
Total Tonnage 680
System kW/Ton 1.051
Chiller kW/Ton 0.712
P-CHWP kW/Ton 0.022
S-CHWP kW/Ton 0.142

CWP kW/Ton 0.111
CT kW/Ton 0.063
Parameters Chiller B2-2 Chiller B2-3

Rated Tonnage 450 450
Actual Tonnage 348.3 332
Chiller Efficiency 0.70 0.72
% of Loading 100 100
Compressor Ampere 401 397
CHW Flowrate 1080 1080
CHWR Temp 12.9 13.2
CHWS Temp 8.6 9.1
Delta T 4.3 4.1
CW Flowrate 1350 1350
CWR Temp 34.5 35
CWS Temp 30.5 31.8
Delta T 4 3.2
From the above analysis, we noted that even though the chiller were operating at full operating current, it
only manage to produce approximately 75 per cent of its rated capacity. This shows that there are
inefficiency that had set in the chiller. These are mainly
1. High condensing condenser water temperature entering the chiller, i.e. 31C
2. Fouling in the condenser tubes
3. Fouling in the cooler tubes
4. Infiltration of air in the refrigeration system
5. Insufficient of refrigerant
6. Cooling tower not able to bring the condenser water temperature
7. High flow rate of chilled and condenser water
We will touch on the enhancement work later in the report so as to improve the chiller efficiency to or near
the nominal chillers efficiency.
3.5.2 Estimated kW/Ton of Chiller Plant at Level 35
During the walk thru audit, two units of 700-ton Carrier 19EB chillers were running in chiller plant located
at level 35. Similarly, the chiller plant at level 35 adopts primary and secondary pumping system, and
rejects heat to the cooling tower installed at level 52 via condenser water pumping system.
Refer to table 3.8, the chiller plant kW/Ton at level 35 is estimated at 1.11 kW/Ton, consumes more
power than chiller plant B2. This is understandable as 19EB is R12 positive pressure chiller, whereas R11

is more efficient negative pressure chiller. Similarly, there is huge potential for efficiency improvement for
chiller plant at level 35.
Table 3.8 Level 35th Chiller Plant kW/Ton Estimation
Rated Input Input Input Running

No. Item Capacity % Load Amp Voltage PF kW Tonnage
1 Chiller 35-1 200 ton 0% 0 415 0.85 0.00 0
2 Chiller 35-2 700 ton 0% 0 415 0.85 0 0
3 Chiller 35-3 700 ton 100% 100 3300 0.85 486 554
4 Chiller 35-4 700 ton 100% 104 3300 0.85 505 542
7 P-CHWP 35-1 5.5 kW 0% 0 415 0.87 0.00
8 P-CHWP 35-2 18.5 kW 0% 0 415 0.87 0.00
9 P-CHWP 35-3 18.5 kW 100% 27 415 0.87 16.63
10 P-CHWP 35-4 18.5 kW 100% 27 415 0.87 16.63
11 S-CHWP 35-1 45 kW 0% 0 415 0.87 0.00
12 S-CHWP 35-2 45 kW 100% 69 415 0.87 43.02
13 S-CHWP 35-3 45 kW 100% 72 415 0.87 45.03
14 S-CHWP 35-4 45 kW 100% 69 415 0.87 43.34
13 CWP 35-1 18.5 kW 0% 0 415 0.87 0.00
14 CWP 35-2 75 kW 100% 0 415 0.87 0.00
15 CWP 35-3 75 kW 100% 101 415 0.87 63.16
16 CWP 35-4 75 kW 0% 92 415 0.87 57.53
19 CT 1 15 kW 100% 0 415 0.87 0.00
20 CT 2 30 kW 100% 0 415 0.87 0.00
21 CT 3 30 kW 100% 43 415 0.87 26.89
22 CT 4 30 kW 0% 31 415 0.87 19.39
Total kW 1,323
Total Tonnage 1,096
System kW/Ton 1.207
Chiller kW/Ton 0.904
P-CHWP kW/Ton 0.030
S-CHWP kW/Ton 0.120
CWP kW/Ton 0.110
CT kW/Ton 0.042
Parameters Chiller 35-3 Chiller 35-4

Rated Tonnage 700 700
Actual Tonnage 554.4 542
Chiller Efficiency 0.88 0.93
% of Loading 100 100
Compressor Ampere 401 397
CHW Flowrate 1680 1680
CHWR Temp 15 14.7
CHWS Temp 10.6 10.4
Delta T 4.4 4.3
CW Flowrate 2100 2100
CWR Temp 38.6 39.7
CWS Temp 32.9 33.8
Delta T 5.7 5.9
From the above analysis, we noted that even though the chiller were operating at full operating current, it
only manage to produce approximately 79 per cent of its rated capacity. This shows that there are
inefficiency that had set in the chiller. These are mainly
1. High condensing condenser water temperature entering the chiller, i.e. 33C
2. Fouling in the condenser tubes
3. Fouling in the cooler tubes
4. Infiltration of air in the refrigeration system
5. Insufficient of refrigerant
6. Cooling tower not able to bring the condenser water temperature
7. High flow rate of chilled and condenser water
We will touch on the enhancement work later in the report so as to improve the chiller efficiency to or near
the nominal chillers efficiency
3.5.3 Estimated kW/Ton of WCPU
Unlike the chiller plant where all the major equipment are located at a centralized location, all the 33 units
of WCPUs are scattered in 16 plantrooms. Spot measurements were taken at two of the WCPUs where
kW/Ton was estimated to represent the kW/Ton of the rests of WCPUs.
Table 3.9 WCPU kW/Ton Estimation
On Off
Fan Cond Cooling
Coil Coil Comp Comp Fan
Unit Model Airflow Motor Pump Capacity kW/Ton
(DB (DB Amp kW kW
Amps kW/Ton Tons
ºC) ºC)
WCPU
50BJ034 8,750 22.8 11 32.6 7.8 19.9 4.8 0.1 24.4 1.11
6-2A
WCPU
50BJ034 8,750 20.9 12.6 38.1 8.0 23.3 4.9 0.1 17.1 1.74
47-1
WCPU 6-2A
This unit was running at almost full load capacity and kW/Ton is estimated at 1.11 kW/Ton. However, the
delta T across the evaporator is almost 12C. This indicates sign of ‘choked’ evaporator coils. The airflow
through the coil could be low hence; we get this huge delta T. The nominal rated capacity is the WCPU is
28.3 R-Ton and the efficiency is between 0.9 to 1 kW/Ton depending on the incoming condenser water
temperature. We will touch on the enhancement work required to push the capacity back to its nominal
rated capacity and efficiency in the following chapter
WCPU 47-1
This was running at part load capacity. The delta T across the evaporator, 8.3C, which was less than the
nominal delta T. This could be due to low charge of refrigerant in the system and that the WCPU was at
its unloading condition. However, the former could be thru as the kW consumption is still high. The
kW/Ton is higher as WCPU is unable to unload efficiently with reciprocating compressor.
Table 3.10 Upper Floor WCPU kW/Ton Estimation
Rated Input Input Input

No. Item Capacity % Load Amp Voltage PF kW
1 CT WCPU 52 -1 700 ton 0% 29 415 0.85 17.72
2 WCPU CWP 1 30 kW 100% 29 415 0.87 18.14
3 WCPU CWP 2 30 kW 100% 30 415 0.87 18.76
4 WCPU 1 28.3 kW 100% 46 415 0.87 28.77 24.4
5 WCPU 2 28.3 kW 100% 46 415 0.87 28.77 24.4
6 WCPU 3 28.3 Ton 100% 46 415 0.87 28.77 24.4
7 WCPU 4 28.3 Ton 100% 46 415 0.87 28.77 24.4
8 WCPU 5 28.3 Ton 100% 46 415 0.87 28.77 24.4
9 WCPU 6 28.3 Ton 100% 46 415 0.87 28.77 24.4
10 WCPU 7 28.3 Ton 100% 46 415 0.87 28.77 24.4
11 WCPU 8 28.3 Ton 100% 46 415 0.87 28.77 24.4
12 WCPU 9 28.3 Ton 100% 46 415 0.87 28.77 24.4
13 WCPU 10 28.3 Ton 100% 46 415 0.87 28.77 24.4
14 WCPU 11 28.3 Ton 100% 46 415 0.87 28.77 24.4
15 WCPU 12 28.3 Ton 100% 46 415 0.87 28.77 24.4
16 WCPU 13 28.3 Ton 100% 46 415 0.87 28.77 24.4
17 WCPU 14 28.3 Ton 100% 46 415 0.87 28.77 24.4
18 WCPU 15 28.3 Ton 100% 46 415 0.87 28.77 24.4
19 WCPU 16 28.3 Ton 100% 46 415 0.87 28.77 24.4
20 WCPU 17 28.3 Ton 100% 46 415 0.87 28.77 24.4
21 WCPU 18 28.3 Ton 100% 46 415 0.87 28.77 24.4
22 WCPU 19 28.3 Ton 100% 46 415 0.87 28.77 24.4
23 WCPU 20 28.3 Ton 100% 46 415 0.87 28.77 24.4
24 WCPU 21 28.3 Ton 100% 46 415 0.87 28.77 24.4
25 WCPU 22 28.3 Ton 100% 46 415 0.87 28.77 24.4
26 WCPU 23 28.3 Ton 100% 46 415 0.87 28.77 24.4
27 WCPU 24 28.3 Ton 100% 46 415 0.87 28.77 24.4
Total kW 745 536.8
Total Tonnage 537
System kW/Ton 1.388
WCPU kW/Ton 1.286
Cooling Tower kW/ton 0.033
CWP kW/Ton 0.069

Table 3.11 Lower Floor WCPU kW/Ton Estimation
Rated Input Input Input

No. Item Capacity % Load Amp Voltage PF kW
1 CT G 4 200 ton 100% 21 415 0.85 12.83
2 CTG 5 & 6 400 ton 100% 21 415 0.85 12.83
3 WCPU CWP 1 22 kW 100% 29 415 0.87 18.14
4 WCPU CWP 2 22 kW 100% 0 415 0.87 0.00
5 WCPU 1 30 kW 0% 46 415 0.87 28.77 24.4
6 WCPU 2 30 kW 0% 46 415 0.87 28.77 24.4
7 WCPU 3 28.3 Ton 100% 46 415 0.87 28.77 24.4
8 WCPU 4 28.3 Ton 100% 46 415 0.87 28.77 24.4
9 WCPU 5 28.3 Ton 100% 46 415 0.87 28.77 24.4
10 WCPU 6 28.3 Ton 100% 46 415 0.87 28.77 24.4
11 WCPU 7 28.3 Ton 100% 46 415 0.87 28.77 24.4
12 WCPU 8 28.3 Ton 100% 46 415 0.87 28.77 24.4
13 WCPU 9 28.3 Ton 100% 46 415 0.87 28.77 24.4
14 WCPU 10 28.3 Ton 100% 46 415 0.87 28.77 24.4
15 WCPU 11 28.3 Ton 100% 46 415 0.87 28.77 24.4
16 WCPU 12 28.3 Ton 100% 46 415 0.87 28.77 24.4
Total kW 389 292.8
Total Tonnage 293
System kW/Ton 1.329
WCPU kW/Ton 1.179
Cooling Tower kW/ton 0.088
CWP kW/Ton 0.062
WCPU unloads by step capacity controls with multiple compressors or by step unloader built in with the
compressor. Thus, efficiency of WCPU fluctuates between 1.11 to 1.74 kW/Ton or even worse
depending on the capacity loading.
3.5.4 Estimated kW/Ton of ACSU
No spot measurement was taken from the air-cooled split units (ACSU). Generally, ACSUs are designed
to operate between 2.6 to 3.0 COP at full load capacity, or in terms of kW/Ton, between 1.17 to 1.35
kW/Ton. However, at part load conditions, the efficiency of ACSUs might deteriorate to 2.0 COP or 1.76
kW/Ton.

3.6 Summary of Estimated kW/Ton of Air-Conditioning System
Efficiencies
Based on the data collected during the walk through audit and estimation of cooling loads by using the
methodology as described in section 3.5, the efficiencies of various air-conditioning systems at Menara
Maybank can be summarized as the following table.
Table 3.10 Summary of Air-Conditioning System kW/Ton of Existing Systems
Cooling Load Power Consumption Efficiency

# System (ton) (kW) (kW/ton)
Chilled Water
System (Chiller
1 1940 2660 1.37
Plant + AHUs/
FCUs)
2 WCPU 650 689 1.33 to 1.39
3 Split Units 152 130 1.17 to 1.76
4 Overall 2700 3466 1.37*
* Weighted average kW/Ton of chilled water, WCPUs and ACSUs.
Overall, the HVAC system at Menara Maybank is operating at 1.20 kW/Ton. The state of the art efficiency
with today’s commercially available and environmentally sound technology for water-cooled chilled water
system is 0.68 kW/Ton. Therefore, the HVAC system efficiency can be improved by up to 43%.
Figure 3.6 Benchmark Current Mixed System at Menara Maybank against Centralized Chilled Water System
0.68 kW/Ton 1.00 kW/Ton 1.20 kW/Ton 2.0 kW/Ton

SOTA Industry Menara Poorly
Average Maybank maintained
(18-yr old system
and system)

4. Immediate Measures for HVAC System Optimization
4.1 Immediate Measures
Even with the Maybank intention of replacing the Chillers, these initiatives will better position the facilities
for the new Chillers in place and is not repetitive of the long term intention that Maybank had position
herself. The short term measures will ensures that the incumbent problem of insufficient cooling will be
improved while the future system replacement will further improve the system efficiency.
4.1.1 Air Handling Units
The physical condition of the cooling coils of the AHU show sign of algae formation across the coils. On
th
average the total CFM that were supplied to the 16 floor is 16,000 CFM. This translates to about 0.8
CFM per square feet. This is below the average requirement of 1.2 to 1.5 CFM per feet for an office area
condition. This also explains the not cooling issues in the respective floors. We would propose that the
AHU be enhanced to improve the cooling deliverables to the floor that it served.
We therefore propose that the following to be done to all the AHU in the building.
1. Actual measurement of the chiller performance and kW of the chilled water system for a week to
benchmark the system efficiency.
2. Chemical cleaning of the cooling coils to maximize the air flow thru it. This need to be done
repeatedly till the required airflow had been achieved thru the cooling coils.
3. Chemical flush of the cooler tubes to improve the AHU cooling coils approach temperature.
4. Check and if necessary replace the belting and drive.
5. Check the ducting work for any leakage thru the ducting system.
6. Re-commission the AHU system and log the cooling area condition.
7. Post measurement of each individual AHU after the re-commissioning work to ascertain the
improved efficiency.
4.1.2 Water Cooled Package Unit at 4-6 and 45-52 system.
The improvement on the refrigeration system of the water-cooled package unit, WCPU, an immediate
affects on the cooling capacity the WCPU units. In addition, the fact the delta T across the WCPU
evaporator coils is higher than design; the improvement in the airflow across the coils will improve the air
distribution thru the floor area and improve the floor cooling. With proper controls, the energy savings thru
the enhancement work would be substantial. Our approach will be to improve the WCPU efficiency to or
near its rated nominal capacity. We

therefore propose that the following to be done on the WCPU units to improve its cooling deliverables and
subsequently improve the energy usage.
1. Actual measurement of the WCPU performance and kW consumption of each WCPU before
the enhancement work for a week to benchmark the current system efficiency.
2. Cleaning of the condenser tubes for the condenser to improve the approach temperature.
The flushing or cleaning of the condenser must be done repeatedly until the required
condenser approach is achieved.
3. Chemical cleaning of the evaporator coils to improve the airflow thru the crequired air flow is
achieved thru the evaporator coil.
4. Check and charge in gas to the refrigeration system till optimum condition.
5. Check and if necessary replace the belting and drive.
6. Check the ducting work for any leakage thru the ducting system.
7. Recommission the WCPU system and log the cooling area condition.
8. Improve the condenser water supply temperature by improving the wet bulb temperature
around the cooling tower. Cleaning of the cooling tower infill and strainers so that we could
get the condenser water supply temp at 28C.
9. Throttle the condenser water flow thru the WCPU units.
10. Post measurement of the WCPU units after the recommissioning work to ascertain the
improved capacity.
4.1.3 Chilled Water System at Basement 2 and 35th Floor
The improvement on the refrigeration system of the chiller will have an immediate effect on the cooling
capacity and thus improve the total cooling deliverables to the building. Our target is to improve the
chilled water efficiency from the existing 1.05 kW/Ton for B2 and 1.2 kW/Ton for 35 th floor plant to about
0.9 and 1 kW/Ton system efficiency respectively. We therefore propose that the following to be done on
the Chilled Water System.
1. Actual measurement of the chiller performance and kW of the chilled water system for a week to
benchmark the system efficiency.
2. Cleaning of the condenser tubes for the condenser to improve the approach temperature.
3. Chemical flush of the cooler tubes to improve the cooler approach temperature.
4. Check the purge unit and if necessary revacuum, pump in the gas and recommission the
refrigeration system.
5. Improve the condenser water supply temperature by improving the wet bulb temperature around
the cooling tower. Cleaning of the cooling tower infill and strainers so that we could get the
condenser water supply temp at 28C.

6. Throttle the condenser water flow thru the chiller condenser.
7. Clean the strainer of the chilled water system.
8. Throttle the chilled water flow thru the cooler tube to get the required delta T.
9. Post measurement of the chilled water system performance after the recommissioning work to
ascertain the improved efficiency.
4.2 Fresh Air Supply
Formerly PAHUs were used in the building to serve the outdoor fresh air to all the air handling units
(AHUs) using in the building. Because insufficient cooling capacity due to the aging chillers, the PAHUs
are no longer in use now. We observed that the CO2 concentration in the building is higher (spot
measurements show fresh air ranging from 10 to 15 cfm per person) than ASHRAE recommendation at
20cfm per person due to lack of the fresh air.
We recommend to install the cooling coil in the PAHU plant to pre-cool the fresh air before delivering the
fresh air to the individual AHU rooms. The infiltration of the outside air can be reduced by pressurizing the
room such that the pressure of the indoor space is higher than the outdoor atmospheric pressure. That
will maintain the comfort level and achieve the higher efficiency of the entire airside systems.

5. HVAC Systems Retrofit Proposal
Menara Maybank was completed and started operation in 1988. The existing HVAC systems have been
running for 18 years. Most of the equipment are approaching the end of average useful lifespan
recommended by ASHRAE. For example, ASHRAE recommended useful lifespan for centrifugal chillers
is 23 years (refer figure 5.1) while the chillers in Menara Maybank have been running for 18 years. If the
replacement of major equipment like chillers is further delay, both the maintenance cost and energy cost
to operate the old machines will continue to escalate.
Figure 5.1 ASHRAE recommended service life of various HVAC system components
The main reason to retrofit the existing chiller plant, besides aging of existing equipment, is to replace the
existing non-environmentally friendly equipment. Both ozone depletion and global warming have
becoming major environmental concerns globally. Refrigerant CFC has already been phased out in
Malaysia back in year 2000 as Malaysia is one of the signatory member of Montreal Protocol. All the
chillers in Menara Maybank are still using CFC R11 and R12 refrigerants. Thus, replacing old CFC
chillers with chlorine-free HFC R134a chillers will enable Menara Maybank to comply to the environmental
requirement of Montreal Protocol.
Replacing old inefficient chillers with highly efficient environmental friendly chillers will also help to reduce
global warming impact. This is because efficient chillers consume less electrical power, indirectly help to

reduce CO2 emission to the atmosphere, and thus, reduce global warming caused by green house effect
which mainly due to CO2 emission.
However, before carrying out replacement project for major equipment, Tatasolusi Pratama recommends
Maybank to perform a detailed energy audit to facilitate retrofitting of existing HVAC systems.
5.1 Benefits of Detailed Energy Audit Exercise
The existing HVAC systems were designed by the M&E engineers before the building was completed. In
general, engineers are conservative in their load calculations and equipment selections. The load
calculations were designed based on conservative assumptions like people density, estimated lighting
watt per floor area, estimated fresh air intake, etc.. Very often, safety factors would be applied to ensure
adequate cooling in the building. While the intent was good as to ensure adequate cooling even if the
system is slightly overloaded or not operating at full capability, too much of a good thing can lead to
inefficient operation. Cooling load measurements derived from a detailed energy audit exercise shall
confirm the actual cooling load profiles. M&E consultant can then design the new chiller plants in
accordance with the actual cooling profiles.
The second benefit of carrying out a detailed energy audit is to ascertain the changes in peak load and
load profile of the building over time. This can be either an increase, such as added equipment, or a
decrease, such as the results of lighting retrofits, change in occupancy or use of space.
The third benefit is the technology changes. Over the years, the technology has enabled huge
improvement on equipment efficiency. For example, over the years, chiller kW/Ton has improved
tremendously from 0.7 kW/Ton twenty years ago to 0.48 kW/Ton today. A detailed energy audit measures
the existing system efficiency. This shall facilitate the estimation of potential efficiency improvement and
thus, estimating the return on investment by retrofitting the existing chiller plant with highly efficient
equipment.
5.2 Detailed Energy Audit
Detailed energy audit or energy audit level III helps to gather enough information on energy consumption,
cooling load profile and facility system efficiency from existing building to implement system engineering.

During a detailed energy audit, Tatasolusi Pratama will install temperature thermistor calibrated to the
accuracy of ±0.01 ºC to measure operating temperature in the plants, e.g. supply and return chilled
water temperatures from the chiller plants, supply and return condenser water temperatures from the
cooling towers. Ultrasonic flowmeters will be used to measured chilled water flow rates and condenser
water flow rates in the chiller plants and the building. This will ensure minimum disruption to building or
system operation while carrying out the detailed energy audit.
The operating conditions, flow and temperatures, will be measured, sampled and data logged every
minute by using laboratory data acquisition controller to ensure highly reliable and accurate data are
being collected.
With the above scientific approach adopted in the detailed energy audit, power consumption pattern and
building cooling load profile can be accurately measured and collected to facilitate further analysis.
Firstly, system efficiency baseline can be ascertained before implementing the retrofit works.
Figure 5.1 System baseline efficiency
System baseline efficiency will enable the designer to quantify potential energy saving through energy
efficiency improvement, and thus, evaluation of Return on Investment (ROI) and Payback period to retrofit
investment can be carried out to justify the retrofit investment.
System baseline will also form the basis for Maybank to get into a performance based energy saving
contract with the retrofit contractor, and thus, giving assurance to Maybank’s investment in retrofitting the
old system. On top of that, potential energy saving can be quantified to generate cash flow positions to
justify the retrofit implementation.

Figure 5.2 Baseline and target new system efficiency
5.3 Detailed Energy Audit Retrofit Approach vs Conventional Retrofit

Approach
The detailed energy audit analysis helps to optimize Maybank’s capital investment and provide a
foundation or baseline for Maybank to measure and verify the actual ROI.
Conventional retrofit approach normally replaces the old chillers with new chillers rated at the same
capacity. For example, there are 3 units 700-ton and 1 unit of 200-ton existing chillers at level 35, the
conventional approach is to replace the old equipment with 3 units of 700-ton and 1 unit of 200-ton new
chillers.
The detailed energy audit retrofit approach will assess the cooling load profile measured during the
detailed energy audit and optimize the new chiller sizing and capital investment.
In summary, based on findings from the walk thru audit, Tatasolusi Pratama proposes Maybank to
consider the following detailed energy audit retrofit plan:
Retrofit Plan:
• Replacing the existing chiller plants at level B2 and 35 with chiller plants at level B2 and
35 re-designed to suit the actual cooling load profile
• Enhance, optimize or even replace the airside systems, WCPU systems and ACSUs to
ensure comfort conditions are not compromised

5.4 Retrofit Plan
Our proposed retrofit plan is to replace the existing chiller plants by re-designing the system based on
actual cooling profiles. The greatest challenge is to bring in new chillers through the criss-cross external
wall structure at level 35.
Figure 5.3 New chiller access at level 35
Most of the new chillers nowadays are modularly constructed. That means most of the new chillers can
be knocked down into three components – compressor, cooler and condenser. These components can
be hoisted separately and pushed through the criss-cross structure one at a time.
The largest component after the knocking down is the condenser. The cross sectional dimensions of the
condenser of a 700-ton chiller are 1495mm x 1016mm (height x width, 4.9ft x 3.33 ft), and the weight is
3726kg or 3.8 tons. A preliminary study shows that the condenser can still be pushed through the triangle
shape access on the criss-cross structure at level 35.
Refer figure 5.4, steel channels can be built to allow the condenser to be moved on rollers into the plant.
If the condenser can be moved through the criss-cross structure, there will not be any issue to move the
cooler and compressor into chiller plant at level 35.
However, the biggest challenge is to construct a temporary crane at the roof to hoist the 3.8-ton
condenser to level 35. Study and approval must be obtained from a qualified civil engineer to ascertain if
installation of such crane at the roof is feasible.

Figure 5.4 Accessibility of the condenser of a 700-ton chiller
Initial study shows the total cost to hoist components of 3 units of 700-ton chillers and 1 unit of 200-ton
chiller to level 35 is about RM 500,000.
We have to evaluate ROI based on capital investment, achievable target system efficiency and potential
energy efficiency to ascertain if the retrofit plan is viable.

6. Energy Economic Analysis
Energy economic analysis has be done to verify the ROI or payback of the Retrofit Plan as proposed in
previous chapter. Energy economic analysis will allow Maybank to decide on a Retrofit Plan that generate
the most energy savings and positive cash flows for the entire useful lifespan of the new HVAC system.
The capital investment, potential energy savings, ROI and payback for conventional one-to-one retrofit
plan, detailed energy audit retrofit plan are summarized as below:
Conventional Retrofit Approach: Replacement of the Chiller Plant on a One on

One Basis
No Description of Work Cost
1 Replacement of 4 chillers – 35th Floor (700-ton x 3 + 200- RM
ton x 1) 6,200,000.00
2 Replace of 4 Chillers – Basement 2 (450-ton x 3 + 200-ton RM
x 1) 5,000,000.00
3 Replace all the WCPUs RM
3,500,000.00
4 Hoisting and Installing Chillers at Level 35 RM
500,000.00
5
Estimated Total Cost RM
15,200,000.00
6
Estimated Savings RM
1,025,000.00
7
Payback Period 14.8 years
Note: Using old TNB tariff rate.

Detailed Energy Audit Retrofit Plan: Replacement of the Chiller Plant with Re-
Chiller Plant Sizing based on Energy Audit Data
The estimated cost of investment is based on assumption that the chiller capacities can
be reduced based on energy audit results and actual cooling load profiles:
1 Replacement of 4 chillers – 35th Floor with re-designed RM
with lower capacities 5,000,000.00
2 Replace of 4 Chillers – Basement 2 with re-designed with RM
lower capacities 4,500,000.00
3 Replace all the WCPUs RM
3,500,000.00
4 Hoisting and Installing Chillers at Level 35 RM
500,000.00
5
13,500,000.00
6
1,100,000.00
7
Payback Period or ROI 12.3 years
Obviously, labor and materials to replace chillers at level 35 take up about 7% of the total cost. Payback
can be further improved by optimize the chiller sizing, and this can only be estimated upon completion of
detailed energy audit.

Immediate Measures (System Optimization and Enhancement Work)
1 AHU Enhancement Work RM
258,000.00
2 WCPU Enhancement Work RM
100,000.00
3 Chiller Optimisation RM
90,000.00
4
448,000.00
5
200,000.00
6
Payback Period or ROI 2.24 years
Note: Using old TNB tariff rate.
Tatasolusi recommends Maybank to adopt immediate measures to optimize and enhance the AHU
systems and WCPU systems. The benefits are improved comfort and immediate energy savings before
carrying out major retrofit at the main chiller plants.

7. Conclusion
Comparison of conventional one-to-one retrofit approach against energy audit retrofit plan at Menara
Maybank can be summarized as follows:
Even though it initially may incur higher cost to conduct a detailed energy audit by the energy consultant
as compared to conventional approach of engaging a M&E consultant alone, the benefits of reducing
capital investment and increase in potential energy cost saving through proper matching of chiller plant
sizing to the actual cooling loads far outweigh the cost of detailed energy audit. The synergy of the
Energy Consultant with the M&E Consultant shall ensure successful implementation of a detailed energy
audit retrofit plan.
Furthermore, Menara Maybank can fully utilize the pre-retrofit energy audit and post-retrofit audit results
to verify the ROI of the retrofit project and use the real time measured data to implement efficiency
sustainability at Menara Maybank for the entire service life of the new chiller plant.
The energy consultant fees shall include detailed energy audit, design and project management of the
retrofit project.

Menara Maybank - Preliminary Energy Walk Thru Audit by Tatasolusi Pratama

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Menara Maybank - Preliminary Energy Walk Thru Audit by Tatasolusi Pratama

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Preliminary Energy Appraisal Report

Tatasolusi Pratama Sdn Bhd

Confidential Page 1 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Confidential Page 2 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Executive Summary ........................................................................................................................ 4

Confidential Page 3 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

kWh Consumption by Usage

Lift & Escalator Others

Confidential Page 4 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Confidential Page 5 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

1.2 Introduction of Tatasolusi Pratama

1.3 Building Descriptions of Menara Maybank

Confidential Page 6 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Electrical Maximum Electrical Demand Electrical Demand Total

Dec-05 2,256,884 5,856 0.208 17.300 469,432 101,308 570,740

Confidential Page 7 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Figure 2.1 Monthly Electric Cost in 2005 vs 2004

Monthly Electric Cost, 2005 vs 2004

Confidential Page 8 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Lift & Escalator Others

Figure 2.3 Breakdown of monthly kWh consumption by usage

Confidential Page 9 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

0 50 100 150 200 250 300

Confidential Page 10 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

3.2 Water-Cooled Chilled Water System

Figure 3.1 One of the chillers at basement 2

Confidential Page 11 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Table 3.1 Chillers operating data as per WTA (Basement 2)

Chiller B2-2 (450 RT) Chiller B2-3 (450RT)

Figure 3.2 Chillers located at Level 35

The Chillers at the Level 35 are running at the following conditions.

Table 3.2 Chillers operating data as per WTA (Level 35)

Chiller 35-3 (700 RT) Chiller 35-4 (700RT)

Confidential Page 12 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Confidential Page 13 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Table 3.5 Condenser water pumps operating data

Confidential Page 14 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Confidential Page 15 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Table 3.6 List of Cooling Towers

Cooling Tower Floor Serving Running Amp

3.2 Water Cooled Package Units (WCPU)

Figure 3.5 One of the WCPUs from Menara

Confidential Page 16 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

3.4 Split Type Air-Conditioning Units

3.5 Methodology of Estimating System Efficiency for Air-Conditioning

Table 3.7 B2 Chiller Plant kW/Ton Estimation

Confidential Page 18 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Parameters Chiller B2-2 Chiller B2-3

3.5.2 Estimated kW/Ton of Chiller Plant at Level 35

Confidential Page 19 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Table 3.8 Level 35th Chiller Plant kW/Ton Estimation

Rated Input Input Input Running

Parameters Chiller 35-3 Chiller 35-4

3.5.3 Estimated kW/Ton of WCPU

Table 3.9 WCPU kW/Ton Estimation

Table 3.10 Upper Floor WCPU kW/Ton Estimation

Rated Input Input Input

Confidential Page 22 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Rated Input Input Input

3.5.4 Estimated kW/Ton of ACSU

Confidential Page 23 of 37 Copyright of Tatasoluti Pratama Sdn Bhd, 2006

Table 3.10 Summary of Air-Conditioning System kW/Ton of Existing Systems

Cooling Load Power Consumption Efficiency

0.68 kW/Ton 1.00 kW/Ton 1.20 kW/Ton 2.0 kW/Ton