Advanced RTU Campaign Webinar June 17, PDF Free Download

Advanced RTU Campaign Webinar June 17, 2013

Agenda Introductions Overview of the Advanced RTU Campaign Michael Deru Walgreens RTU Replacement Program Jason Robbins and Nirmal Sekhri Advanced Packaged Rooftop Unit Controls: Results from Field Demonstrations Srinivas Katipamula 1

Advanced RTU Campaign (ARC) Overview What: Move the commercial building market to greater adoption of high efficiency RTU solutions Follow-on to RTU Challenge and RTU retrofit controls demonstrations Who: Organizers: ASHRAE and RILA Supporters: Utility programs, efficiency organizations, manufacturers, contractors Participants: Building owners Department of Energy provides technical support When: Launched May 30, 2013 and runs through November 2014 2

1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Number of Units (1,000s) Why RTU s? RTUs cool over 60% of U.S. commercial building floor area Lots of 10 to 20 year old RTUs installed Replacement is often only after failure 10,000 9,000 8,000 Air-Source Heat Pumps Unitary Air Conditioners 7,000 6,000 5,000 4,000 Large stock of 6-18 year old equipment 3,000 2,000 1,000 0 Source: AHRI 3

High-Efficiency RTU Solutions Luckily there are great solutions on the market! New high-efficiency RTUs can be up to 50% more efficient than existing units Retrofit controls can save up to 40% with paybacks as short as 2 years 4

What are RTU Retrofit Controls? For units <10 years old and > 5-7 tons of cooling capacity Essential features: Variable or multi-speed fan control Integrated economizer control Demand controlled ventilation Desirable features: Variable capacity compressors Fault detection and diagnostics Remote monitoring Reduce RTU energy consumption by up to 40% with a 2-4 year payback 5

What is a High-Efficiency RTU Replacement? Retirement before failure and replacement with high-efficiency RTU High Efficiency = Consortium for Energy Efficiency (CEE) Tier 2 and above Example: 10-ton RTU 90.1-1999 90.1-2001 90.1-2004 90.1-2010 CEE Tier II RTU Challenge EER EER EER EER IEER EER IEER IEER 8.7 10.1 10.1 11 11.2 12 13.8 18 6

Resources: ARC website www.advancedrtu.org 7

ARC Supporters Who Utilities Efficiency Programs Manufacturers / Distributors Installers RTU enthusiasts Sign-up on the ARC website www.advancedrtu.org Promote the campaign and recruit participants and other supporters Review and/or provide campaign materials 8

Participate in ARC Sign-up on the ARC website www.advancedrtu.org Evaluate your RTUs and share information with ARC (evaluation form coming soon!) RTU Comparison Calculator www.pnnl.gov/uac/ Search for incentives and financing: Local utility or DSIRE, www.dsireusa.org Federal tax deductions (expires 12/31/2013) - www.179d.energy.gov Database of incentives and financial offerings on ARC website Find eligible products: < 5.5 tons, CEE/EPA product database > 5.5 tons, AHRI product database 9

Motivation for Participating Eligible for 50% discount on six ASHRAE publications after sharing RTU evaluations (For a limited time: June 19- July 19) Why Replace or Retrofit Unit age/expected end of life Repair history and cost to repair Depreciation value Expense or capital expenditure Phase out of R22 Customer and/or employee comfort Corporate energy/environmental/sustainability policies Preparation for building upgrade for sale or lease 10

Other Things to Keep in Mind Include with other retrofits to increase overall project performance and success Properly size the new units New units are often 25% - 50% smaller than the original Load Calculations ACCA Manual N or ASHRAE Standard 183 Follow a quality installation specification ANSI/ACCA 5 QI Properly commission and complete TAB Follow-up with a quality maintenance plan ANSI/ASHRAE/ACCA Standard 180 11

ARC Technical Resources Guidelines to determine whether to retrofit or replace Performance data from DOE and other demonstrations Energy savings calculators Procurement specification (performance, installation, and quality maintenance) Example quality maintenance contract Case studies 12

Market and Financial Resources Barriers Potential solution(s) First cost drives buying decisions A list of RTU incentives and financing resources Manufacturer supporter financing Utility supporter relationships with local debt providers Lack of awareness of the benefits of high efficiency units Split incentives between owners and tenants Building Owner and Operator Barriers to RTU Efficiency Financial and technical calculators Case studies Strong campaign partners Examples of energy aligned- leases or owners/tenants that have successfully negotiated upgrades Uncertainty/mistrust about savings claims Lack of expertise about how to specify advanced equipment/ what to buy 13 3 rd party demonstrations Case studies Sample procurement specifications A list of RTU incentives and financing resources

Case Studies and Making the Business Case Building owner and operator case studies Leverage third party demonstrations Target case studies at a variety of building types Highlight conditions where RTU replacements and retrofits make the strongest business case Utility case studies How are utilities attributing energy savings and demand reduction to RTUs and RTU controls? What is the estimated cost effectiveness of an RTU? Case studies reduce the time, effort, and dollars needed to be spent on making the case to regulators 14

What s Next in ARC Continuous improvement in campaign materials feedback welcome RTU evaluation and screening checklist Procurement specification More case studies Potential new technical studies Impact of maintenance Degradation of RTUs Improved calculators Evaluation of other technologies to include in ARC Energy recovery ventilators Evaporative precooling 15

Meeting Agenda 10k foot Replacement Program Overview, 2010-2013 Program Data, 2010-2013 Process Savings, 2013 Opportunity Benefits

Program History Contractor Evolution 2010 10-12 Contractors 2013 1 Contractor Initiative Evolution 2010 7-8 Points per Project (50/50) 2013 30 Points per Project (22 Trane & Installing Contractor/8 WAG) Budget Evolution 2010 ~360 Sites, 2013 ~500 Sites

Walgreens 2010 & 2011 Rooftop Replacement Highlights Total RTU s 2,438 Total Stores 628 Average RTU s per store 3.798 (4 units per store) WAG handled TAB direct Average Curb Spend per adapter - $750 (for 4 Curb adapters per store) Drive market need for units made for flexible replacement without need for adapter curbs Installing Contractor Install: Flat rate volume based fee (across country) Walgreens 2010 Retrofit # s

Walgreens 2012 Rooftop Replacement Highlights Total RTU s 1,614 Total Stores 362 Average RTU s per store 4.458 (5 units per store) TAB shifted to install contract, SAS, Dual Stage Motors, BCI boards added to BOM Average Curb Spend per adapter - $750 (for 4 Curb adapters per store) Drive market need for units made for flexible replacement without need for adapter curbs Installing Contractor Install: Flat rate volume based fee (across country) Walgreens 2012 Retrofit # s

Walgreens 2013 Rooftop Replacement Highlights Total RTU s 1,071 Total Stores 183 Average RTU s per store 5.85 (6 units per store) TAB shifted to install contract, SAS, Dual Stage Motors, BCI boards, & SZVAV added to BOM Average Curb Spend per adapter - $750 (for 4 Curb adapters per store) Drive market need for units made for flexible replacement without need for adapter curbs Installing Contractor Install: Flat rate volume based fee (across country) Walgreens 2013 Retrofit # s

Process Improvements through Lessons Learned Curb Adapter Analysis - Sites reviewed by Installing Contractor Tonnage Review/TRACE 700 Load Analysis/NPV Options Review/WAG Criteria & Past Installations EPACT Analysis, Calculations, & Paperwork for Walgreens Filing $0.00 Additional Investment by Walgreens WAG R13 Process Savings

Build a winning Business Case Find the right balance for your organization Initial Investment TCO Maintenance Savings WAG R13 Process Savings Energy Savings

Benefits of HVAC system re-design and right-sizing - Tonnage Review/TRACE 700 Load Analysis/NPV - Options Review/WAG Criteria & Past Installations 165 Total Stores $791,895 in Material Savings via Right-Sizing Process» Average reduction of 5 Tons per project $327,522 in Labor Savings via Right-Sizing Process»$1,119,417 in Total Savings via Right-Sizing Process WAG R13 Process Savings

Rebates and Incentives - EPACT Analysis, Calculations, & Paperwork for Walgreens Filing - http://apps1.eere.energy.gov/b uildings/commercial/179d/ 165 Stores Trane/Installing Contractor handling all Calculations, Prep & Signatures» Other groups charging for Site Review & Signatures WAG $1,096,200 R13 in Process anticipated Savings Gross EPACT Benefit to WAG

Compare to the cost of no action Critical to financially compare current operating model to proposed. I.E. Planned replacement vs. emergency replacement. Requires deep internal knowledge of current operating models

Missed opportunities of Run to Fail model No Opportunity for Re-Design/Tonnage Reduction/Downsizing Opportunity Cost of $4,799 per site, Material Only No Opportunity for EPACT Calcs/Site Review/Signatures Opportunity Cost of $2,325 (Net) per site No Opportunity for Mobilization Savings (6 installs/6 RTU s vs. 1 install/6 RTU s) Opportunity Cost of $3,667 per RTU ($5,500 vs $11,000) Opportunity cost of 15-25% premium for Expedited Curb Adapters Reduced Opportunity for Volume Discounts through high volume purchases

Avoided Maintenance Capital New units cost less to maintain than old units Reduced Opportunity for Maintenance Savings Maintenance Costs average $0.40/Sqft (industry average)= $5,800/store/year (>10 years)

Energy Savings Potential Average Unit 12 Years ago, EER = 8.5 Degradation Factor Added, EER = 6.5 (Conservatively) Possibility for collaboration or independent testing to validate equipment degradation impact over time New units EER (CEE Tier 2) = 12.63 IEER (Multi-Stage Units) = 15+ Financial Analysis 14,500 Sqft Store 6.5 EER = 1.846 kw/ton 12.63 EER = 0.95 kw/ton 15 IEER = 0.8kW/ton Financial Results 35 tons @ 6.5 EER = 64.61kW @4,000 hours = 258,440 kwh @ $0.10/kWh = $25,844/year 31 tons @ 12.63 EER = 29.45 kw @4,000 hours = 117,800 kwh @$0.10/kWh = $11,780/year

Ancillary Benefits Update Equipment for EMS & Controls Compatibility New Technologies to reduce maintenance time New Technologies to take advantage of Flex Capabilities Dual Fuel (Heating) Single point Economization Move from Belts to Direct Drive, 100% Reduction in Tonnage = Direct Humidity Control = Creature Comfort + No Moisture on Saleable product Process Management Stocking of what? Who to call? When will they get here? Where should they ship? Who installs them?...

Thousands of Aging Stores

Advanced Packaged Rooftop Unit Controls: Results from Field Demonstrations Srinivas Katipamula, Ph.D., Pacific Northwest National Laboratory

Why is there a Need for an Advanced RTU Controller? Packaged air conditioners and heat pumps (RTUs) are used in about 58% of all cooled commercial buildings, serving about 69% of the cooled commercial building floor space (EIA 2003) Packaged A/C uses 0.9 quads of electric cooling annually and 0.4 quads of heating (source) Most RTUs operate inefficiently lack of advanced controls constant supply speed fan and constant ventilation lack of equipment maintenance Operating efficiency can be improved significantly with the use of advanced control strategies: integrated economizers variable or multiple speed supply fan control demand controlled ventilation and variable or multiple capacity control 33

Advanced RTU Controls: Accomplishments and Progress Installation of all controllers for both DOE and BPA projects complete Continuing to monitor RTUs in the field Savings analysis underway and final report is being drafted, which will be released in August 2013 after BPA/DOE review Also coordinating work with Center for Energy and Environment in Minnesota, which is also evaluating advanced control products http://www.pnnl.gov/main/publications/external/technical_reports/ PNNL-20955.pdf http://www.pnnl.gov/main/publications/external/technical_reports/ PNNL-21944.pdf 34

ESTIMATED COST SAVINGS FOR COMMERCIAL BUILDINGS WITH ADVANCED RTU CONTROLS FY 11 EnergyPlus Simulation Results June 18, 2013 35

Advanced RTU Controller: Field Test Measurement Plan K W T Compressor Outside Air Mixed Air Heating Coil Supply Air T K W Low Voltage Terminal Board T Controls Section T CO2 Return Air The following parameters will be measured: outdoor-air temperature, return-air temperature and CO 2, mixed-air temperature, supply-air temperature, outdoor-air damper signal, supply fan power and total unit power. Additional parameters from the RTU controller will also be recorded (fan, compressor, economizer status, etc.) 36

Advanced RTU Controller: DCV and Fan Controls Verification Supply fan controls vary by mode of operation Automated database scripts are used to verify operation Demand control ventilation CO 2 level is maintained below 1,000 ppm, again automated scripts will be used to verify this operation 10 rules created to verify operations, which focus on: Fan speeds in different RTU operating modes, such as ventilation and economizing Outdoor air damper control depending on the sensed CO 2 concentration For each operation, automated database scripts are used to identify exceptions to the rules Exceptions are further investigated Mode Supply Fan Speed Advanced (%) Standard (%) Economizer 90 100 1 st Stage Cooling 75 100 2 nd Stage Cooling 90 100 1 st or 2 nd Stage Heating 90 100 Ventilation 40 100 37

Advanced RTU Controller: Field Test Economizer Controls Verification To verify the economizer controls, the data collected from the RTU is processed with PNNL s Outdoor Air Economizer (OAE) Diagnostician OAE Diagnostician will identify problems with economizer controls and ventilation operations OAE originally funded by Building Technologies Office and enhanced using funding from California Energy Commission Public Interest Energy Research and the Washington State Project Air Handler, Date and Time Current Conditions Impacts Potential Causes Suggested Actions 38

Advanced RTU Controls: Energy Savings Estimation Tool PNNL is using Energy Charting and Metrics (ECAM) Tool to estimate energy savings Semi-automated approach PNNL has further automated the tool Ability to normalize the savings to a typical year (e.g. TMY3) http://www.pnl.gov/buildingretuning/ecam.stm 39

Advanced RTU Controller: Field Test Saving Analysis Approach Original Data Filtering Data Aggregation and Normalization Regression Model Development Measured Energy & Cost Savings Normalized Annual Energy & Cost Savings Identify and remove outlier data Generate daily RTU energy use and the average outdoor air temperature ECAM Tool E cool = C 0 + C 1 (T T CCP ) + E heat = H 0 + H 1 (T HCP T) + Apply the pre-retrofit regression model to the post-retrofit period Apply the pre- and post-retrofit regression models to TMY3 weather data 40

Advanced RTU Controls: Electricity Savings (%) from Field Measurements Electricity consumption from 51 RTUs were analyzed 17 RTUs are heat pumps and the rest are air conditioners with gas furnaces 41

Advanced RTU Controls: Distribution of Electricity Savings and Expected Payback Installed cost of advanced controls: 1 to 3 hp motor (up to 15-ton capacity) is approximately $3,500 + $600-$800 (labor) 5 to 7.5 hp motor (up to 25-ton capacity) is approximately $4,100 + $600-$800 (labor) Detailed economic analysis is not yet complete, but paybacks for units with 7.5 ton capacity and higher likely will be 3 or less with no utility incentives Smaller units (<7.5 ton) will have slightly higher payback 42

Final Report Details Description of Advanced RTU Controls Metering and Monitoring Plan Savings Estimation Methodology Validation of Advanced RTU Controls and Economizer Controls Energy Savings Estimates Detailed Economic Analysis Discussion and Recommendations Including rules-of-thumb for screening potential retrofit units 43

Advanced RTU Controls: Next Steps Develop a deployment and communication plan and help BTO/CBI (and BPA) promote the use of advanced controls for existing RTUs thru RTU replacement campaign initiated by BTO s Commercial Buildings Integration Program Develop web-based tool to help users estimate potential savings from use of advanced controls for their specific climate and building type 44