Nordex India Manufacturing Private Limited
Central HVAC & Humidity Control System
for Nordex India Manufacturing Pvt. Ltd.
Client Overview
Nordex India Manufacturing Private Limited, established on September 16, 2020, is a private, unlisted company registered in Bangalore, Karnataka. The company specializes in manufacturing machinery and equipment for the wind energy sector, particularly wind turbine components like rotor blades. The company’s Thiruvallur, Chennai plant is one of India’s most advanced blade manufacturing facilities, designed for high-precision moulding, lamination, curing, sanding, and finishing processes.
Project Requirement
In 2019, during the planning phase of their Thiruvallur, Chennai plant, Nordex India approached Weather Controlling Solutions India Pvt. Ltd. (WCSIPL) to design and implement a fully integrated HVAC system for their 1,000,000 sq.ft. facility. The objective was precise temperature and humidity control across three large hangars, blade finishing areas, material storage, and corporate offices. The facility produces wind turbine blades up to 98 meters in length and 6 meters in height, where dust, moisture, and temperature control are critical to ensure dimensional stability, resin curing, and flawless surface finishing.
Process Challenges
- Massive Volume Handling: Hangars over 27 meters high requiring uniform air distribution and airflow balance.
- Dust & Moisture Control: FRP lamination generates micro-dust; humidity control is essential for resin curing and surface finish.
- Zonal Segmentation: Multiple hangars, storage, and office zones requiring individual and centralized HVAC control.
- Energy Efficiency: Continuous operation demanded optimized systems for reduced energy consumption.
- Complex Control & Automation: Coordinating 100 AHUs across 100 locations required central and individual control, including monitoring and adjustments via central plant control.
WCSIPL’s Turnkey Solution
WCSIPL delivered a highly integrated HVAC system combining chilled water systems, DX AHUs, VRF, and split ACs, with full central plant control and hydropneumatic pumping to manage all cooling and water distribution.
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Parameter
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Specification
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Total Covered Area
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10,00,000 sq.ft.
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Building Height
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27 meters
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Plant Location
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Thiruvallur, Chennai
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Building Height
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7 meters
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Total Installed Capacity
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Cooling Systems
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Central Air-Cooled Chiller Plant, DX AHUs, VRF, Split Units
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AHU Deployment
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100 AHUs placed across 100 locations
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Control System
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Fully centralized plant control with individual AHU control
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Pumping System
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Hydropneumatic system for chilled water and process water distribution
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Zones Covered
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3 Hangars + Blade Joint Route + Office + Storage
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Key System Deliverables
- Central Chiller Plant: 8 x 400 TR air-cooled chillers serving ~6,00,000 sq.ft.
- DX AHU & RH-Controlled Units: 1 x 700 TR DX AHU for joint and finishing hangar with precise temperature & RH control
- Supplementary Systems: 300 HP VRF system for offices, ductable ACs, and split ACs for auxiliary zones
- 100 AHUs: Strategically placed at 100 locations for uniform airflow and temperature distribution
- Centralized & Individual Control: Each AHU communicates with the central plant for monitoring and zone-specific adjustments
- Hydropneumatic Pumping System: Ensures continuous, balanced chilled water distribution to all AHUs and process units
- Complete Turnkey Execution: Ducting, insulation, MS structural works, cabling, panels, and commissioning
Project Scope Executed by WCSIPL
- Complete design, supply, installation & commissioning
- Central chiller plant setup and hydraulic balancing
- Installation of 100 AHUs with central & individual control integration
- Hydropneumatic system for optimal water distribution
- Air ducting, insulation, and acoustic treatments
- Zonal RH and temperature control logic
- Testing, balancing, and performance verification
Performance Results
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Parameter
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Target
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Performance
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|---|---|---|
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Process Temperature
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26°C ± 2°C
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■ Maintained
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Relative Humidity
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55% ± 5%
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■ Stable
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Dust Concentration
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<100 µg/m³
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■ Maintained
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Energy Efficiency
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Benchmark vs Traditional Systems
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■ 30–35% Savings
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System Uptime
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24x7
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■ 99%
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AHU Control
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Central + Individual
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■ Fully Functional
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Key Benefits to Client
- Enhanced production quality: defect-free blade finish with precise temperature & RH control
- Improved process consistency: uniform resin curing and surface quality
- Energy savings: optimized HVAC operation reduces consumption by ~35%
- Advanced automation: central plant control with individual AHU flexibility
- Continuous operation: redundancy ensures minimal downtime
- Complete turnkey delivery by WCSIPL
Client Feedback
“The scale and precision required in wind blade manufacturing make environmental control critical. WCSIPL’s HVAC system, with 100 AHUs and centralized control, has proven reliable,
energy-efficient, and perfectly suited for our blade production requirements.”
— Plant Head, Nordex India Manufacturing Pvt. Ltd.
Conclusion
This project exemplifies WCSIPL’s capability in delivering industrial-scale HVAC systems with advanced automation, hydropneumatic distribution, and precise environmental control for high-volume, process-critical manufacturing facilities.
About WCSIPL
Weather Controlling Solutions India Pvt. Ltd. (WCSIPL) specializes in industrial, process, and cleanroom HVAC turnkey solutions for sectors including renewable energy, food, pharma, and high-precision manufacturing.
Visit: www.wcsipl.com | www.wcsipl.net