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
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.
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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.
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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
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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.
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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.
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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.
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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.
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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…)
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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.
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11. Multiple CT control loops to optimize the chiller
plant while protecting the chillers
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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.
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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.
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14. Nozzle Spray pattern – very little
coverage of fill – design flow rate
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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
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16. Bottom of the fill with the fan in bypass –
100% speed, design flow rate
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17. Bottom of fill with the CT fan off, design
flow rate
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18. One cell open to flow – Design flow –
1100 GPM
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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27. Status at a Glance Efficiency Speedometer
The LOBOS
Efficiency
Speedometer is
dynamic in nature.
The levels of
efficiency change
with the loads.
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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.
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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.
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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.
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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!
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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.
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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
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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.
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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.
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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
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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
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38. Case Study 600 B Street San Diego
Optimized Plant vs. Normal Operation/Equipment
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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.
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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
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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.
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42. Complete Day Performance:
Tons & kW/ton
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43. Complete Day Performance:
Tons and kW/ton
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44. Case Study
10-Story Office Building; 80% Energy Efficiency Improvement
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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.
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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.
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47. 2040 Main Street
750 Ton VFD Chiller System
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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.
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49. LOBOS Demand Response
(LOBOS DR)
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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.
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51. LOBOS DR Web Home Page
LOBOS allows
customers to
login from the
web.
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52. AHU Selection Dashboard
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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.
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54. LOBOS Demand Response
Central Plant
Configuration
Dashboard
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55. LOBOS Demand Response
Typical Air
Handler
Configuration
Dashboard
55
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56. LOBOS Demand Response
Our Air
Handler
Summary
Page allows
you to view
what stage
each
individual
AHU is
curtailing
too.
56
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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
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58. Automated Demand Response
LOBOS ADR
Configuration
& Set-up
Dashboard
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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
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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).
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61. Demand Response and Automatic AHU Coasting
Cycle Showing Fan Speed Reduction after 5:00 PM
Based on Floor Loading
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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.
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63. Q&A
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64. Presented by:
Scot M. Duncan, P.E.
sduncan@roi-engineering.com
949 370 8582
enerliance.com
roi-engineering.com
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