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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
Better Buildings Alliance 1
• 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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Nu
mb
er
of
Un
its
(1,0
00
s)
Air-Source Heat Pumps
Unitary Air Conditioners
Source: AHRI
Large stock of 6-18 year
old equipment
Better Buildings Alliance 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
Better Buildings Alliance 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
Better Buildings Alliance 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
Better Buildings Alliance 6
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
Better Buildings Alliance 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
Better Buildings Alliance 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
Better Buildings Alliance 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
Better Buildings Alliance 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
Better Buildings Alliance 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
• 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
Better Buildings Alliance 13
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
Better Buildings Alliance 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
Better Buildings Alliance 15
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
Better Buildings Alliance 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
Better Buildings Alliance 34
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.)
Better Buildings Alliance 36
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
Better Buildings Alliance 37
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
Better Buildings Alliance 38
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
Better Buildings Alliance 39
Advanced RTU Controller: Field Test Saving
Analysis Approach
Better Buildings Alliance 40
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
Better Buildings Alliance 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
Better Buildings Alliance 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
Better Buildings Alliance 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
Better Buildings Alliance 44
• 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 [email protected]
Advanced RTU Campaign (ARC) Overview
Better Buildings Alliance 45