Navy Case Study - Base Load Optimization
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Navy Case Study - Base Load Optimization

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See How the Navy Used the Load Based Optimization System to Save a Boatload of Energy!...

See How the Navy Used the Load Based Optimization System to Save a Boatload of Energy!
We cut the energy consumption by over 70% at this 10 year old Navy Chiller Plant!
If you are serious about cutting energy consumption and reducing operating costs, you'll want to be at this presentation!

“Large Temperature Differential” design will be discussed. Typical TES systems that were a part of the Southern California Edison “Permanent Load Shift” chilled water storage pilot program operated with 25°F to 30°F chilled water temperature differentials, while the PG&E site peaked out with a 44°F temperature differential (not a typo!), with typical summer operation floating between 30°F and 34°F TD’s. The PG&E 900 ton chiller plant all-in efficiency averaged around 0.50 kWh per ton-hour while making 35°F chilled water for the TES system during the TES charge cycle.

A preliminary analysis using all of the above strategies and an innovative dehumidification/ reheat system to treat 1,000,000 CFM of makeup air at a large chip fab yielded potential savings of over 27,000,000 kWh per year, and over 400,000 therms per year in natural gas savings.

These design, Demand Response and optimization strategies can be applied across a wide variety of facility types, from tilt ups with large RTU’s to Commercial office space, to Universities and Colleges, to military, prison, manufacturing and technology sites.

Please join us for an entertaining and educational meeting!

Scot M. Duncan, P.E. Biography

With 39 years of field, design and plant operational experience, the bio gets really long! We’ll just bracket it to cut down on your boredom reading it…Scot started in the business at age 12 helping his dad install an early version of an automation system (the Honeywell Delta 2000 for you old guys) at the Irvine Company Newport Center high rise facilities. Since then, he has been involved in hundreds of successful and sometimes counter-intuitive energy efficiency projects.

He is a “Subject Matter Expert” for the U.S. Army Corps of Engineers on 14 different topics, ranging from Net Zero Energy HVAC designs, to high efficiency dehumidification/reheat systems, to HVAC optimization to TES. Scot is a co-author of the International Energy Agency (IEA) ECBCS Annex 46 “Energy and Process Assessment Protocol” (soon to be on Oprah’s “must read” list and a New York Times Best Seller wanna-be…).

Scot is a Past President of the AEE SoCal Chapter (1990) and is Vice President of Retrofit Originality Incorporated, and President of Enerliance. He has provided over 100 chiller plant, HVAC and TES energy efficiency and design strategy training seminars since 1985, and has not been booed off the stage even once that he’ll admit to.

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Navy Case Study - Base Load Optimization Navy Case Study - Base Load Optimization Presentation Transcript

  • SDG&E – Pt. Loma Naval BaseChiller Plant Upgrade Cuts Energy by over 70% Annuallyusing the Load Based Optimization System [LOBOS]California Center for Sustainable Energy 9-14-11 Proprietary and Confidential. Not for distribution.
  • • We offer this presentation in the memory of Gary Gates, a Navy man that fought tirelessly to save energy while improving working conditions for Navy personnel. He is sorely missed by all who knew him. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 2
  • GE Ecomagination Challenge• The Ecomagination Challenge is a worldwide competition sponsored by General Electric to identify viable strategies to reduce energy waste and consumption, as well as viable methods to effectively produce renewable energy and improve grid/system performance on a global basis.• Out of 3,800 entries received and evaluated by GE, Enerliance is the only firm with two entries in the top 100. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 3
  • Why LOBOS?“Poor controls can waste more energy than great equipment can save.”11.9 MPG on Prius with Prius with “Efficient” HVAC “Load Based”the Prius Control HVAC Control Strategies 99 MPG 16 MPG ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 4
  • Project Description • The Building 56 Chiller plant at the Pt. Loma Naval Base serves 24/7 loads including data centers, office areas and computerized training labs and other classified areas that we could tell you about, but then we’d have to kill you. • The project consisted of adding one new 450 ton VFD centrifugal chiller to the two existing 350 ton VFD centrifugal chillers, adding VFD’s to the primary and condenser water pumps, removing a multitude of tertiary pumps from the buildings and installing the Load Based Optimization System (LOBOS) to optimize the system. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 5
  • History• The Navy had installed a well marketed optimization system from another firm on a previous project, but after two years of operation, it was not meeting expectations.• When this project was brought up, there was a huge pushback from many in the Navy, due to concerns about not meeting expectations.• They reviewed real operational data from several Load Based Optimization System projects and decided to utilize this system for their project. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 6
  • History• Prior to the Load Based Optimization System (LOBOS) installation, the plant was run 24/7 with fixed CHWS temperatures and differential pressure setpoints, as there was no feedback from the loads to allow the system to be run more effectively.• The timing of the cooling load needs at night and on weekends is based on the use of the data centers and trainers, and is totally unpredictable. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 7
  • Results• After one year of operation, the M&V process has shown that the results have exceeded savings expectations by over 50%.• There has been a net reduction of energy used in the chiller plant of over 70%, based on a separate utility meter.• Additional scope incorporated into the project have added approximately 1,000 MWH of savings that were not expected. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 8
  • Plant load 325 tons, Total Plant = 0.28kW/ton (note the OSA humidity at 105% - previouslyexisting sensor, and why we do not use RH in any of our code…) ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 9
  • Many existing loads still have 3-way valves, so secondary flow and pump energy isstill higher than it needs to be. Low CHW temperature differential from 3-ways alsodrives primary pump energy higher than it needs to be, so we could eventually getdown to 0.22 to 0.25 kW/ton for the entire plant under similar conditions. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 10
  • Multiple CT control loops to optimize the chiller plant while protecting the chillers ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 11
  • Obvious Savings Directly Attributed to LOBOS Savings during “Limited Reset Operation” during commissioning were running 45% until Nov. when we were directed to shut LOBOS off. Savings for “Equipment only” changes ran about 12% for the month that LOBOS was shut off. When restarted, savings went back to 45% -50%. When full LOBOS resets were allowed in June, savings climbed to 73%- 75% per month. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 12
  • Savings during “Limited Reset Operation” duringcommissioning were running 45% until Nov. when wewere directed to shut LOBOS off. When restarted,savings went back to 45% -50%. When full LOBOSresets were allowed in June, savings climbed to 73%-75% per month. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 13
  • Nozzle Spray pattern – very littlecoverage of fill – design flow rate ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 14
  • Approximate 14” to 16” wide dry area at the bottom of the fill with the CT fan inbypass (100% speed) and design CDW flow ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 15
  • Bottom of the fill with the fan in bypass – 100% speed, design flow rate ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 16
  • Bottom of fill with the CT fan off, design flow rate ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 17
  • One cell open to flow – Design flow – 1100 GPM ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 18
  • Solids Buildup with new fill. It is obvious where water is flowing and where water is not flowing.There is more surface area with solids build up than there is clean area where water is flowing. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 19
  • Scaling/Solids• It can be seen from these pictures that scale is already forming on the fill which has been installed for approximately 6 months.• We rectified the issue by installing nozzles that were two sizes smaller, and getting up inside the towers and directing the spray nozzles to wet the entire fill at low flow rates.• Works even better at high flow rates.• Allows much better use of the CT system, as well as reducing CDW pump energy waste and improving chiller energy performance. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 20
  • Future Savings Projects atPt. Loma• New fan coil units are being selected at 350 feet per minute face velocity to double CHW system temperature differential, improving overall system efficiency markedly.• LOBOS being applied to new FCU’s. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 21
  • LOBOS• Minimize Financial Risk, Maximize Owner Savings• LOBOS Energy Efficiency (EE) and LOBOS Demand Response (DR) patent protected logic are pre-programmed, pre-tested and pre-commissioned software and hardware solutions that maximize owner savings while minimizing the financial risks and loss of time associated with installing advanced control system routines. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 22
  • LOBOS: How It Works• Energy Efficiency and Demand Response control logic is contained in the LOBOS system.• LOBOS integrates into the existing DDC Systems via the OPC server, LonTalk or BACnet software or hardware driver.• The operating data from the HVAC system is gathered by LOBOS; the control setpoints are calculated and sent back out to the local DDC panels for an optimized PID loop control. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 23
  • Simple & Sustainable• Energy Efficiency – Most Energy Management Systems (EMS) leave a substantial amount of savings on the table – In many cases, complex or non- adjustable optimization programs are disabled or overridden so Facility Engineers can keep tenants comfortable. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 24
  • LOBOS Control Strategy• Make it consistent / repeatable from building-to-building.• Make it user-friendly so the Operator can make adjustments within certain parameters.• Make it self tuning to account for system/climate variations.• Improve tenant experience, reduce energy costs and consumption. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 25
  • Pick the Right Optimization Strategy!• Central Plant Optimization routines must look at the site loads – without knowing AHU load information, you cannot maximize energy savings, or respond to load changes properly.• AHU Optimization routines are required to minimize energy use and promote occupant comfort! Don’t ignore 40% to 50% of the energy consumption of the cooling system!• The System Must be Operator Friendly – If the person that designed it cannot explain it in an understandable manner to the people that operate the facility, it is too complex. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 26
  • Status at a Glance Efficiency Speedometer The LOBOS Efficiency Speedometer is dynamic in nature. The levels of efficiency change with the loads. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 27
  • AHU Set-up Screen This page presents an overview of the information for each particular AHU. There is general information for the central plant and a summary of the WCAH values being utilized to drive LOBOS. On this page, the user can opt in/out the particular AHU to be monitored by LOBOS. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 28
  • AHU Supply Temperature Tuning The Supply Air Temperature Setpoint tuning page allows for setting up the supply fan speed setpoint, which should be set as the value that the operators would like to see the fan speed run at. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 29
  • AHU Supply Duct Static Tuning The Supply Static Pressure Setpoint tuning page gives adjustability for how aggressive the setpoint will change to widening return air temperature deviation and space temperature deviation. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 30
  • LOBOS Air Handler Overview Provides an overview of values used in establishing Worst Case AHU Size/ Criticality/ Distance. All floors are not loaded alike – the Plant Optimization system must consider all loads! ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 31
  • LOBOS Central Plant Optimization To make the CHWS temperature and CHW DP adjustments faster or slower, the slide bars can be used to double the gain, or cut the gain in half, or any amount between them. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 32
  • Effects of Changing CDW Temp Setpointon VFD Chiller System EfficiencyTemp Scale kW/ton Scale Condenser water return temperature Condenser water supply temperature Chiller kW per ton of cooling Chilled water return temperature Chilled water supply temperature ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 33
  • Case Study – 75% savings at theNavy Point Loma Project• This project installed one new variable speed chiller, instituted a “variable everything” chilled water pumping system and implemented the LOBOS software into the existing EMS.• Overall annual efficiency is running around 0.52 kWh per ton and at around 200 tons the plant runs at around 0.36 kW/ton.• The plant operation should be reduced by over 1,500 hours per year, due to “Thermal Flywheel” logic in the control scheme that shuts down chillers and uses the cold water that is in the pipes to meet small loads. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 34
  • Building 56 at Naval Base PointLoma – kWH monthly savings. At the current savings rates, the chiller plant / LOBOS upgrade savings will exceed projected savings by more than 55 percent. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 35
  • Monthly Average kWh Consumption for Pre and Post TES System Upgrade [From Utility Meter] 18350 Von Karmen Chiller Plant Monthly Energy Consumption (average, excluding 2003 due to low occupancy) 500,000 400,000kWh/mo 300,000 200,000 100,000 1 2 3 4 5 6 7 8 9 10 11 12 Post Modification Pre-Modification ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 36
  • Average Monthly Energy SavingsFrom TES Upgrade Project 18350 Von Karmen Chiller Plant Monthly % savings (average, excluding 2003 due to low occupancy)60%50%40%30%20%10%0% 1 2 3 4 5 6 7 8 9 10 11 12 Chiller Plant Monthly % savings ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 37
  • Case Study 600 B Street San Diego Optimized Plant vs. Normal Operation/Equipment ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 38
  • Case Study Inland Center Mall• LOBOS control strategies can optimize CHW supply temperature and CDW supply temperature, as well as AHU variables.• Total chiller plant energy efficiency on the following sample project is averaging less than 0.50 kW/ton, even on 100°F days.• Total Plant includes all chillers, chilled water pumps, condenser water pumps and cooling towers. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 39
  • E-mail from Dave Manley – 86%HVAC System Energy ReductionGentlemen,• If we reduce usage anymore…we can turn everything off and go home! Overall usage down an amazing 55.89% from last year. HVAC usage down 86.59% from last year, triple checked figures. Duncanization didn’t effect Tower water usage like it did last month. Total monthly breakdown usage shows HVAC = 22%, INTERIOR = 50%, EXTERIOR = 28%. Only increase was in #2 COM. AREA due to increase in RMU’s and contractors using common area power during TI’s.• David Manley | Operations Manager• Inland Center Mall• 500 Inland Center• San Bernardino, CA, 92408 ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 40
  • Chiller Plant Snapshot: InlandCenter Mall Chiller @ 0.32 kW/ton Total chiller plant @ 0.45 kW/ton, including pumps, chillers and CTF’s 100°F OSA. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 41
  • Complete Day Performance:Tons & kW/ton ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 42
  • Complete Day Performance:Tons and kW/ton ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 43
  • Case Study10-Story Office Building; 80% Energy Efficiency Improvement ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 44
  • Total Plant Efficiency @ 0.38 kW/Ton At 33% load on the chiller, the total HVAC system, including fans and central plant equipment is using 0.51kW per ton. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 45
  • Total Plant Efficiency @ 0.33 kW/Ton At 55% load on the chiller, the total HVAC system, including fans and central plant equipment is using .52kW per ton. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 46
  • 2040 Main Street750 Ton VFD Chiller System ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 47
  • Energy Efficiency Summary• Properly designed and applied TES systems can reduce site and source energy consumption and enable wind power to become a viable part of the energy infrastructure.• Energy Efficiency, Demand Response and Demand Reduction Technologies are not mutually exclusive!• You can start with the most efficient design possible, which reduces demand, then add demand response software and Thermal Energy Storage (TES) if/when appropriate.• With TES, airside Demand Response controls can be added to further reduce site demand, over and above the central plant peak demand savings.• It is possible to reduce energy consumption at the site and source, while simultaneously reducing peak electrical demands and T&D congestion and improving occupant comfort.• It is not cheap, but the benefits and GHG emission reductions are substantial. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 48
  • LOBOS Demand Response (LOBOS DR) ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 49
  • LOBOS DR• Typical DR Control systems require substantial manual intervention and often do not get utilized because of the manpower costs associated with enabling them.• The LOBOS DR 10 Stage is a fully automatic DR control system that can be applied to an individual building or across an entire portfolio.• The system is as close to set it and forget it as you can get.• Depending upon the facility size and the demand reduction potential at the site, the SCE Technical Installation Incentive may cover the entire cost of the DR system, thus eliminating any owner out of pocket expense.• On a Portfolio-level project, incentives from the larger facilities can be applied to offset the costs for the smaller facilities. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 50
  • LOBOS DR Web Home Page LOBOS allows customers to login from the web. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 51
  • AHU Selection Dashboard ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 52
  • Portfolio Bid Allocation Dashboard The Portfolio Demand Response Module is intended to be a master control for the individual site DR programs. It will allocate individual kW reduction values to the various sites if they are enabled for DR control. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 53
  • LOBOS Demand Response Central Plant Configuration Dashboard ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 54
  • LOBOS Demand Response Typical Air Handler Configuration Dashboard 55 ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 55
  • LOBOS Demand Response Our Air Handler Summary Page allows you to view what stage each individual AHU is curtailing too. 56 ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 56
  • LOBOS Demand Response Dashboard allows you to schedule your individual building on a rotating block curtailment based on the value you input and the time you schedule the event. 57 ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 57
  • Automated Demand Response LOBOS ADR Configuration & Set-up Dashboard ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 58
  • LOBOS Demand Response Lighting Equipment -up to 20 different zones can be incorporated Select the stage # from the individual drop down menu to begin turning off the lighting group when the stage selected is activated (set to zero to Disable DR Control) 59 ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 59
  • LOBOS Demand Response Miscellaneous Equipment - up to 20 different zones can be incorporated Select the stage # from the individual drop down menu to begin turning off the lighting group when the stage selected is activated (set to zero to disable DR). ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 60
  • Demand Response and Automatic AHU CoastingCycle Showing Fan Speed Reduction after 5:00 PMBased on Floor Loading ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 61
  • Summary• LOBOS Design and Control strategies save energy while improving tenant comfort and temperature control.• By packaging the LOBOS system and using it in conjunction with the existing EMS network infrastructure, costs can be dramatically reduced.• User flexibility is enhanced by allowing the operators to tune their facilities without having to enter the EMS programming code.• LOBOS helps reduce cooling system related energy consumption by 30% to 50% or more.• LOBOS has been integral to the success of many energy savings projects.• LOBOS enables you to easily tune your system, which is the key to its long-term success. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 62
  • Q&AROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 63
  • Presented by: Scot M. Duncan, P.E.sduncan@roi-engineering.com 949 370 8582 enerliance.com roi-engineering.com ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 64