Advanced RTU Campaign...Jun 17, 2013  · Advanced RTU Campaign (ARC) Overview 2 Better Buildings...

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

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• 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

Advanced RTU Campaign (ARC) Overview

Better Buildings Alliance 2

• 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

Why RTU’s?

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Air-Source Heat Pumps

Unitary Air Conditioners

Source: AHRI

Large stock of 6-18 year

old equipment

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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

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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

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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

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Resources: ARC website www.advancedrtu.org

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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

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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

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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

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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

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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

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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

• Financial and technical calculators

• Case studies

• Strong campaign partners

Split incentives between owners and

tenants

Examples of energy aligned- leases or owners/tenants that

have successfully negotiated upgrades

Uncertainty/mistrust about savings

claims

• 3rd party demonstrations

• Case studies

Lack of expertise about how to

specify advanced equipment/ what

to buy

• Sample procurement specifications

• A list of RTU incentives and financing resources

Building Owner and Operator Barriers to RTU Efficiency

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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

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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

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Walgreens RTU Replacement Program

Jason Robbins, Walgreens Co.

Nirmal Sekhri, Trane

6/17/13

©2013 Walgreen Co. All rights reserved.

Meeting Agenda

• 10k foot Replacement Program Overview, 2010-2013

• Program Data, 2010-2013

• Process Savings, 2013

• Opportunity Benefits

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

Program History

Walgreens 2010 Retrofit #’s

• 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 & 2011 Rooftop Replacement Highlights

Walgreens 2012 Retrofit #’s

• 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 Rooftop Replacement Highlights

Walgreens 2013 Retrofit #’s

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 Rooftop Replacement Highlights

WAG R13 – Process Savings

• 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…

Process Improvements through Lessons Learned

WAG R13 – Process Savings

Build a winning Business Case

Initial Investment

Maintenance Savings Energy Savings

TCO

Find the right balance for your organization

WAG R13 – Process Savings

- 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

Benefits of HVAC system re-design and “right-sizing”

WAG R13 – Process Savings

- 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

$1,096,200 in anticipated

Gross EPACT Benefit to WAG

Rebates and Incentives

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

• 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

• No Opportunity for Re-Design/Tonnage Reduction/Downsizing

• Opportunity Cost of $4,799 per site, Material Only

Missed opportunities of “Run to Fail” model

• 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)

Avoided Maintenance Capital

• 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

Energy Savings Potential

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

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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

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June 18, 2013 35

FY 11 EnergyPlus

Simulation Results

ESTIMATED COST SAVINGS FOR COMMERCIAL BUILDINGS WITH ADVANCED RTU CONTROLS

Advanced RTU Controller: Field Test

Measurement Plan

The following parameters will be measured: outdoor-air temperature, return-air temperature and CO2, 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.)

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T

T

Low Voltage

Terminal Board

Return

Air

Outside

AirSupply Air

T

Mixed Air

Controls Section

T

HeatingCoil

Compressor

K

W

K

W

CO2

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

– CO2 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 CO2 concentration

For each operation, automated database scripts are used to identify exceptions to the rules

Exceptions are further investigated

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Mode

Supply Fan Speed

Advanced

(%)

Standard

(%)

Economizer 90 100

1st Stage Cooling 75 100

2nd Stage Cooling 90 100

1st or 2nd Stage Heating 90 100

Ventilation 40 100

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

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Current Conditions

Potential Causes

Air Handler, Date and Time

Suggested Actions

Impacts

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

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Advanced RTU Controller: Field Test Saving

Analysis Approach

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Original Data Filtering

Data Aggregation and

Normalization

Identify and remove outlier

data

Generate daily RTU energy use

and the average outdoor air

temperature

Regression Model

Development 𝐸𝑐𝑜𝑜𝑙 = 𝐶0 + 𝐶1 ∗ (𝑇 − 𝑇𝐶𝐶𝑃)+

𝐸ℎ𝑒𝑎𝑡 = 𝐻0 + 𝐻1 ∗ (𝑇𝐻𝐶𝑃 − 𝑇)+

ECAM Tool

Measured Energy & Cost

Savings

Apply the pre-retrofit regression

model to the post-retrofit period

Normalized Annual

Energy & Cost Savings

Apply the pre- and post-retrofit

regression models to TMY3

weather data

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

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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

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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

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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

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• 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

• Contact us at info@advancedrtu.org

Advanced RTU Campaign (ARC) Overview

Better Buildings Alliance 45