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SDG&E – Pt. Loma Naval Base
Chiller Plant Upgrade Cuts Energy by over 70% Annually
using 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 = 0.28
kW/ton      (note the OSA humidity at 105% - previously
existing 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 is
still higher than it needs to be. Low CHW temperature differential from 3-ways also
drives primary pump energy higher than it needs to be, so we could eventually get
down 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” during
commissioning were running 45% until Nov. when we
were directed to shut LOBOS 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.   13
Nozzle Spray pattern – very little
coverage 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 in
bypass (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 at
Pt. 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 Setpoint
on VFD Chiller System Efficiency
Temp 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 the
Navy 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 Point
Loma – 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

         400,000
kWh/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 Savings
From 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 Reduction
Gentlemen,
• 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: Inland
Center 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 Study
10-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 Street
750 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 Coasting
Cycle Showing Fan Speed Reduction after 5:00 PM
Based 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&A
ROI | 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

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Navy Case Study - Base Load Optimization

  • 1. SDG&E – Pt. Loma Naval Base Chiller Plant Upgrade Cuts Energy by over 70% Annually using the Load Based Optimization System [LOBOS] California Center for Sustainable Energy 9-14-11 Proprietary and Confidential. Not for distribution.
  • 2. • 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
  • 3. 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
  • 4. 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
  • 5. 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
  • 6. 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
  • 7. 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
  • 8. 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
  • 9. Plant load 325 tons, Total Plant = 0.28 kW/ton (note the OSA humidity at 105% - previously existing sensor, and why we do not use RH in any of our code…) ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 9
  • 10. Many existing loads still have 3-way valves, so secondary flow and pump energy is still higher than it needs to be. Low CHW temperature differential from 3-ways also drives primary pump energy higher than it needs to be, so we could eventually get down 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
  • 11. Multiple CT control loops to optimize the chiller plant while protecting the chillers ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 11
  • 12. 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
  • 13. Savings during “Limited Reset Operation” during commissioning were running 45% until Nov. when we were directed to shut LOBOS 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. 13
  • 14. Nozzle Spray pattern – very little coverage of fill – design flow rate ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 14
  • 15. Approximate 14” to 16” wide dry area at the bottom of the fill with the CT fan in bypass (100% speed) and design CDW flow ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 15
  • 16. 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
  • 17. Bottom of fill with the CT fan off, design flow rate ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 17
  • 18. One cell open to flow – Design flow – 1100 GPM ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 18
  • 19. 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
  • 20. 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
  • 21. Future Savings Projects at Pt. 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
  • 22. 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
  • 23. 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
  • 24. 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
  • 25. 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
  • 26. 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
  • 27. 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
  • 28. 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
  • 29. 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
  • 30. 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
  • 31. 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
  • 32. 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
  • 33. Effects of Changing CDW Temp Setpoint on VFD Chiller System Efficiency Temp 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
  • 34. Case Study – 75% savings at the Navy 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
  • 35. Building 56 at Naval Base Point Loma – 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
  • 36. 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) 500,000 400,000 kWh/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
  • 37. Average Monthly Energy Savings From 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
  • 38. Case Study 600 B Street San Diego Optimized Plant vs. Normal Operation/Equipment ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 38
  • 39. 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
  • 40. E-mail from Dave Manley – 86% HVAC System Energy Reduction Gentlemen, • 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
  • 41. Chiller Plant Snapshot: Inland Center 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
  • 42. Complete Day Performance: Tons & kW/ton ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 42
  • 43. Complete Day Performance: Tons and kW/ton ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 43
  • 44. Case Study 10-Story Office Building; 80% Energy Efficiency Improvement ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 44
  • 45. 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
  • 46. 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
  • 47. 2040 Main Street 750 Ton VFD Chiller System ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 47
  • 48. 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
  • 49. LOBOS Demand Response (LOBOS DR) ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 49
  • 50. 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
  • 51. LOBOS DR Web Home Page LOBOS allows customers to login from the web. ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 51
  • 52. AHU Selection Dashboard ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 52
  • 53. 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
  • 54. LOBOS Demand Response Central Plant Configuration Dashboard ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 54
  • 55. LOBOS Demand Response Typical Air Handler Configuration Dashboard 55 ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 55
  • 56. 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
  • 57. 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
  • 58. Automated Demand Response LOBOS ADR Configuration & Set-up Dashboard ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 58
  • 59. 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
  • 60. 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
  • 61. Demand Response and Automatic AHU Coasting Cycle Showing Fan Speed Reduction after 5:00 PM Based on Floor Loading ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 61
  • 62. 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
  • 63. Q&A ROI | Retrofit Originality Incorporated Proprietary and Confidential. Not for distribution. 63
  • 64. 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