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Army Installations Management Command (IMCOM), US Department of Energy, Ft. Lee and The PERTAN Group
September 19, 20, 2009 Fort Lee, VA Presented by Scot M. Duncan, P.E. Vice President Retrofit Originality Incorporated 21382 Countryside Drive Lake Forest, CA 92630 949 370 8582 www.roi-engineering.com sduncan@roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
J.1
Use Variable Frequency Drives (VFDs) for the Primary Chilled Water pumps above 5 HP
A VFD allows the equipment speed to be controlled to match the need of the loads it serves, rather than running at full speed any time it is running. Installation of VFDs on the primary chilled water pumps will allow the speed of the pumps to be varied in response to changes in the cooling loads and chilled water system temperature differentials. Since the power demand of the primary chilled water pump motor varies approximately to the 2.5 power with speed (it is not quite a cubic relationship in the installed world), reducing the pump speed to 70% when the chiller load is around 70% will result in a primary chilled water pump energy savings of approximately 55% to 60%. At low loads, reducing the speed to 50% when the chiller load is around 40% or less will result in a primary chilled water pump energy savings of approximately 80%. Since the chillers spend the majority of their time operating below 70% of their design cooling capacity, the system energy savings can be substantial.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
P o w e rD ra w%
J.2 Use Variable Frequency Drives (VFDs) for the Condenser Water Pumps
A VFD allows the equipment speed to be controlled to match the need of the loads it serves, rather than running at full speed any time it is running. Installation of VFDs on the condenser water pumps will allow the speed of the pumps to be varied in response to changes in the cooling loads. Since the power demand of the condenser water pump motor varies approximately to the second power with speed, (due to the fixed minimum lift conditions of an atmospheric cooling tower, the savings does not correspond to a cubic relationship) reducing the speed to 70% when the chiller load is around 70% will result in a condenser water pump energy savings of approximately 50%. At low loads, reducing the speed to 50% when the chiller load is around 50% or less will result in a condenser water pump energy savings of approximately 75%. We typically do not recommend taking the condenser water pump speed down below approximately 50%, as the savings are minimal below that level, and we need to pay attention to the minimum allowable flow rate over the cooling towers, which is typically in the 50% of design flow range.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Most operating engineers dont have PhDs, and dont want HVAC and control systems that require a PhD to understand.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Overview
Merely having great equipment and a fantastic system design does not guarantee that a system will be energy efficient. Typical energy efficient control strategies leave a substantial amount of savings on the table.
Control system strategies that cannot be easily understood by the operating staff will quickly be disabled, and the system will revert to manual operation, and savings will be lost.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Summary
Poor control strategies can waste more energy than great equipment can save.
The controls must adapt to changing end use loads and conditions and allow the operating staff the ability to tune the system to meet the needs of the various connected loads.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Sample VSE/LOBOS Design and Control Logic Results 103F red line
= Less
Chiller, Approx 0.35 kW/ton, blue line Cooling Tower, Approx 0.08 kW/ton, white line Chilled Water pump, Approx 0.04 kW/ton, pink line Condenser water pump, Approx 0.03 kW/ton, green line
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AHU Summary
100 degrees outside 52.7 F CHW supply temperature Max 54.5F supply air temp. on all AHUs
degree approach temperature between the CHWS temp and the supply air temp leaving the coils. This allows very high CHW temperatures and thus
very high system efficiencies. This compares to typical designs that use coils that provide a 10F to 13F approach temperature. .
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Load Based Optimization on AHU 56F at 0.49 INWC @ 10th Floor AHU@0.24 kW/T & Total HVAC sys @ 0.64 kW/T
Penthouse fan system serves all 10 floors with 0.49 static pressure. Old setpoint was 4+
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Total Plant Efficiency @ 0.38 kW/T Total HVAC System (including Supply and Return Fans) @ 0.51 kW/Ton (VSE/LOBOS)
Dont just look at kW per ton! It can be extremely misleading! Low Temp Air Extreme Test - 39F Air, 0.15 INWC static pressure 0.03 AHU kW/Ton, 0.49 Total HVAC system kW/Ton
While this looks impressive from a kW/ton basis, the dehumidification load to provide 39F air temperatures increased the tonnage dramatically, so overall energy use went up, not down.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Temp Scale
kW/ton Scale
Condenser water supply temperature Chiller kW per ton of cooling Great with LOBOS, 36% worse W/O LOBOS Chilled water supply temperature Chilled water return temperature
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Discussion, continued
The first test, shown in the preceding page, shows that the chiller energy efficiency is running at approximately 0.33 kW per ton, prior to the start of the test. This is excellent efficiency, as most chillers installed today operate between 0.60 and 1.5 kW per ton of cooling. With LOBOS, the condenser water temperature is running at approximately 68F, while the chilled water temperature is running at approximately 50F.
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Discussion, continued
We manually raised the condenser water setpoint to 80F from the automatically controlled setpoint of 68F to determine what effect a normal operating strategy would have on chiller system performance. Many facilities routinely operate their condenser water systems at between 80F and 85F, which are the typical design points for chillers when they leave the chiller factory.
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Discussion, continued
As can be seen, the chiller efficiency was made dramatically worse, increasing from 0.33 kW per ton to 0.45 kW per ton, using 36% more energy to deliver the same amount of cooling. The chiller energy increased from 332 kW to 452 kW, an increase of 120 kW. There was a savings in cooling tower energy of approximately 40 kW by letting the temperature rise, but the net effect on the system was an increase of 80 kW, or approximately 21% more energy to provide the same level of cooling. When the condenser water temperature was released back to LOBOS operating controls, the efficiency was returned to the previously obtained levels.
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Discussion, continued
This also shows that a facility can be designed with excellent cooling equipment, but if it is operated and controlled in a normal manner, the efficiency can suffer in a rather dramatic fashion compared to the potential efficiency. Remember Bad Controls Can Waste More Energy Than Good Equipment Can Save.
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Control Strategy
Make it understandable. Make it consistent/repeatable from plant to plant. Make it tunable by the Operator (within limits) Make it self tuning.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
This screen lets you set the level of importance for each AHU a lab unit gets greater weight than a less critical unit, the further out units get more weight than the close in units, and big AHUs get more weight than smaller AHUs.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
D.2.2.8
Supplying nearly saturated 55 F air into a humid space results in condensation in the spaces, which can lead to mold and mildew problems. Electric or hot water reheat systems are sometimes employed to decrease the RH of the supply air to the spaces to reduce the potential for condensation, but these systems are typically turned off in the field to reduce energy use. Inefficient air dehumidification results in significant repair and maintenance costs. The cost of mold remediation outweighs the total first cost of the HVAC system by an order of magnitude over the life of the HVAC system. Changing dehumidification/reheat system design strategy can reduce energy consumption and cooling and reheat loads, improve IAQ, and reduce the potential for mold growth in occupied spaces. These factors will reduce the level, frequency, and expense of remediation that seems to occur on a regular basis.
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Moisture Control
In order to reduce the potential for biological issues, the building envelope and HVAC system must be designed in concert to properly control moisture. Relative Humidity in the facility must be maintained within acceptable boundaries to promote occupant comfort and health, while reducing the potential for biological issues.
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Dehumidification/Reheat Systems
Many areas in the continental United States only have dehumidification problems in the summer. Other, more far flung locations require continual dehumidification and reheat to maintain comfort conditions and reduce biological issues.
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Supply air temperature is 10F above the dewpoint temperature. For DOAS-HEDS, the supply air temperature can be 20F above the dewpoint temperature.
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Normal AHU System Chiller Plant Load + Reheat Energy (BTUH) 460013 340795 227500 108160
High Efficiency Dehumidification System (HEDS) Chiller Plant Load + Reheat Energy (BTUH) 219240 148330 81250 30400
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Leaving Conditions
DB 98
WB 82
DB 65
Dewpoint 45
Normal DOAS System Chiller Plant Load + DX Subcooling + Reheat Energy (BTUH) 1561813
High Efficiency Dehumidification System (HEDS-DOAS) Chiller Plant Load + DX Subcooling + Reheat Energy (BTUH) 1126150
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com
J.6 Install A Continuous Commissioning, Monitoring and Verification System to Maintain Savings Persistence of the Chiller Plant and HVAC Systems
Software would then be implemented to calculate the efficiency of each piece of equipment, and then trends and alarms would be set up so that there would be a historical database of equipment and system performance. The alarms would be triggered when the system or equipment started operating outside the boundaries set during system startup.
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J.7 Install Water Source Heat Pumps (WSHPs) To Augment the Capacity of the Hot Water Boiler, and To Reduce the Cooling Load on the Existing Chiller Systems When Heat Is Required. A 20 ton WSHP can deliver approximately 320,000 BTUH of heat when it is loaded up. In many cases, the chilled water temperatures that are delivered to the facilities may be too high to adequately cool the facility, and may also be too high to adequately dehumidify the building. In these cases, small WSHPs can be used to reduce the CHWS temperature entering the building while simultaneously dumping the excess heat into a water storage tank for the domestic water loads. In cases like these, dry coolers should be installed to act as a heat rejection source for the WSHP when the domestic water system can no longer accept any more heat, but there is still a need for the cooling system capacity/temperature to be augmented. Water temperatures of 120F to 135F can be obtained.
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J.8 Develop an HVAC and Control System Design Criteria for New and Retrofit Projects.
Weather Correct Standard Designs for the various areas of the country should be developed for Barracks, DFACs, Offices etc. Regional differences must be accounted for in the envelope and HVAC designs.
J.8 Develop an HVAC and Control System Design Criteria for New and Retrofit Projects.
The design-build method seems to be delivering systems and designs that may provide an inexpensive first cost, but have higher than necessary lifecycle costs. Since we are still living with WWII era facilities, it is safe to say that lifecycle costs should be an important consideration.
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J.8 Develop an HVAC and Control System Design Criteria for New and Retrofit Projects. A design standard for each different climate type should be developed with substantial input from the operating staff, and from Subject Matter Experts familiar with dehumidification and control system design and function in the field. Once implemented, the savings associated with standardized system designs and installations will result in millions of dollars per year in avoided energy, maintenance and biological remediation costs.
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J.8 Develop an HVAC and Control System Design Criteria for New and Retrofit Projects. A design standard will also lessen the costs to perform system design and engineering reviews, as standardized designs will be able to be utilized by the local design engineering firms. This will have the added benefit of educating these firms for work in the private sector, allowing their clients to reduce the lifecycle costs of their facilities, and helping America to reduce energy waste and remain competitive with other nations.
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Summary
A recent, Peer Reviewed report in the ASHRAE Journal found that cooling coil face velocities in the 250 to 350 feet per minute range offer the best lifecycle cost, in contrast with the old school practice of sizing cooling coils at 500 to 550 feet per minute face velocity. We have been recommending low face velocity coils for years and have found it to be true.
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Blow thru coils can increase CHW system TD by 34% to 65%+ and decrease peak day cooling loads by 5% or more.
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Subcooling the air due to fan heat added downstream of the coil occurs with this design High air and water pressure drops Typical coil size 4 to 6 row, 550 FPM face velocity Fixed, or poorly reset, setpoints for static and temperature. 1.5 to 2 and 55F are typical AHU setpoints. High pressure drop 2way or 3-way valves
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No subcooling of air due to fan heat added upstream of the coil CHW TD increased by over 165% (24 vs. 9) Desired Coil Size 8 row, 350 FPM face velocity Low air and water DPs Static and temperature setpoints continually reset based on the loads (LOBOS) Low pressure drop 2-way valves Allows chillers in series and substantial pumping savings
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Draw Thru 6 R 550 FPM Coil vs. Blow Thru 8 R 350 FPM Coil
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6R 550 FPM Draw thru vs Blow thru and 8R 550 FPM Draw thru vs Blow thru
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6R 350 FPM Draw thru vs Blow thru and 8R 350 FPM Draw thru vs Blow thru
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Draw Thru 6 R 550 FPM vs. Blow Thru 8 R 350 FPM for 100% OSA system
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Summary
To reduce energy consumption, you need to improve heat transfer efficiency:
Utilize large face area cooling and heating/reheat coils to maximize system temperature differentials and minimize air and water pressure losses. Large cooling coils reduce air pressure drops and allow the use of high chilled water supply temperatures, while still dehumidifying, raising chiller system efficiency. Large face area heating and/or reheat coils reduce air pressure drops and allow the use of low hot water supply temperatures. This can allow the effective use of low quality reclaimed heat, and/or highly efficient condensing boilers.
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Summary
Energy Conservation = water conservation.
If a cooling system is water cooled, saving energy will reduce the amount of heat that has to be rejected by evaporating water, so water savings will result.
It may be possible to capture and reuse condensed moisture off of the cooling coils.
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The lower the relative load and the greater the heat transfer surface area, the closer the approach temperatures can be. The closer the approach temperatures can be, the lower the lift can be. The lower the lift, the more efficient the chiller can be (within limits).
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Fully Loaded VFD chiller @ 0.35 kW/Ton VFD Chiller Efficiency is more related to lift than to load
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Copyright 2009 Retrofit Originality Incorporated. Not for reproduction or distribution without written permission from ROI www.roi-engineering.com