1 Refrigerated Warehouses Stakeholder Meeting 1 California Statewide

1 Refrigerated Warehouses Stakeholder Meeting #1 California Statewide Utility Codes and Standards Program Portland Energy Conservation, Inc. Va. Com Technologies Heschong Mahone Group, Inc April 15, 2010 04/15/2010 Energy for Change™

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouse 2011 Title 24 Stakeholder Meeting Welcome and Introductions Michele Friedrich, PECI 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 2

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Agenda ● 10: 00– 10: 20 Introduction ● 10: 20– 10: 35 Overview/History ● 10: 35– 11: 15 Model & Data Analysis ● 11: 15 -12: 00 2011 Measures ● 12: 00 -12: 45 lunch ● 12: 45 -2: 30 2011 Measures (cont) ● 2: 30 -2: 45 Acceptance Tests ● 2: 45 -3: 00 Wrap up 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 3

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Ground Rules ● For those attending by telephone/web ● ● We want to hear your concerns. ● ● ● Opposing viewpoints are encouraged. We are seeking information, not resolution. Time is limited ● ● ● Please DO NOT place your phone on HOLD. We do not want to hear your hold music. Please mute your microphone, unless you want to speak. Ask questions/comment by “chat” or by voice. Hold questions/comments until the comment periods. Raise your hand be acknowledged by presenter. Clearly state your name and affiliation prior to speaking. Speak loudly for the people on the phone. Minutes and presentation material will be distributed. If you are attending by phone, DO NOT place your phone on HOLD. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 4

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Schedule of Refrigerated Warehouses Stakeholder Meetings ● There will be at least four refrigerated warehouse stakeholder meetings: ● March 17 and April 15, 2010 present scope, including: : ● ● ● August 2010 present findings, including: : ● ● Code change direction and possible options Methodology of analysis Results of data collection and analysis Cost effectiveness “Strawman” proposed code language September 2010 seek final feedback on proposed code : language ● All meetings can be attended remotely. ● Please sign-in for all future meeting announcement mailings. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 5

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouse 2011 Title 24 Stakeholder Meeting Stakeholder Process Cathy Chappell, HMG 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 6

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM IOU Support for 2011 Title 24 ● The California Investor Owned Utilities (IOUs) are actively supporting the California Energy Commission (CEC) in developing the state’s building energy efficiency standard (Title 24). ● Their joint intent is to achieve significant energy savings through the development of reasonable, responsible, and cost-effective code change proposals for the 2011 code update, and beyond. ● As part of the IOU effort, at the request of the CEC, we are hosting stakeholder meetings to get industry input and feedback on our code change proposals. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 7

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Code Change Activity ● 2011 T-24 base code ● 2011 reach standard ● ● Voluntary standards for local govts. Green Building Standard ● Toward Zero Net Energy goal ● ● 2014 T-24 Future reach codes 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 8

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Requirements for a Successful Code Change To be included in code, a measure must: ● ● Be cost-effective according to the Time Dependent Valuation (TDV) life-cycle costing methodology set out by the California Energy Commission (CEC) Be possible to implement using equipment that is readily available from multiple providers (or that is reasonably expected to be available following the code change). 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 9

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Schedule: CEC Key Dates ● Mar 2010 - Dec 2010 ● ● CEC develop foundation IOUs: ● ● Conduct research, and cost effectiveness analysis Present results at stakeholder meetings ● Dec 2010 ● IOUs finalize code change proposals for submittal to CEC ● Feb 2011 ● CEC opens Rulemaking for Title 24, develop 45 -day language ● June 15, 2011 ● Title 24 Adoption date ● Jan. 1, 2013 ● Title 24 Implementation date 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 10

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Stakeholder Meetings Purpose ● Publicize code change proposal ● Present to and solicit feedback from stakeholders on: ● ● Methodology Technology options Market status Draft code language ● Gather additional information from stakeholders on: ● ● Best practices Product/technology availability Market penetration data Cost data 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 11

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Specific Stakeholders Identified ● ASHRAE- American Society of Heating, Refrigerating and Air ● ● ● ● Conditioning Engineers AHRI- American Heating And Refrigeration Institute IIAR- International Institute Of Ammonia Refrigeration GCCA – Global Cold Chain Alliance (IARW, IACSC) Equipment manufacturers Consultants, energy modelers, etc Refrigerated warehouse building owners City and County code officials Equipment distributers and suppliers Refrigerated warehouse designers Investor Owned Utilities California Energy Commission California Air Resources Board Non Governmental Organizations 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 12

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 CASE Process Overview Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 13

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouse 2011 Title 24 Stakeholder Meeting Overview of 2008 Title 24 for Refrigerated Warehouses§( 126) Michele Friedrich, PECI 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 14

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Applicability ● Refrigerated Warehouse with Cold or Frozen Storage > 3, 000 ft 2 Exceptions ● Appliance efficiency (Title 20) applies to refrigerated space < 3, 000 ft 2 ● Areas designed solely for quick chilling or freezing 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 15

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Insulation SPACE Frozen Storage SURFACE Min R-VALUE (°F hr ft 2/BTU) R-36 Wall R-36 Floor Cold Storage Roof/Ceiling R-36 Roof/Ceiling R-28 Wall R-28 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 16

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Underslab. Heating ● Electric resistance heat shall not be used for the purposes of underslab heating. ● Exception: Thermostatically controlled and disabled during summer on-peak period defined by local utility. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 17

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Fan-powered Evaporators ● Single-phase fan motors < 1 HP and < 460 V shall be electronically commutated motors (ECM). ● Fans shall be variable speed, speed controlled in response to space conditions. ● Exception: evaporators served by a single compressor without unloading capability. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 18

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Fan-powered Condensers ● Condensers for ammonia systems shall be evaporatively cooled. ● Design condensing temp for evaporative condenser < design Twetbulb plus: ● ● ● 20 F when design Twetbulb ≤ 76 F, 19 F when 76 F< design Twetbulb < 78 F 18 F when 78 F ≤ design Twetbulb 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 19

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Fan-powered Condensers ● Design condensing temperatures for Air-cooled condensers: ● ≤ the design drybulb temperature plus 10 F for frozen storage. ● ≤ the design drybulb temperature plus 15 F for cold storage. ● Exception: Unitary condensing units 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 20

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Fan-powered Condensers ● Condenser fans shall be continuously variable speed and the speed of all condenser fans serving a common high side are controlled in unison. ● Min condensing temperature set point 70 F or less using ambient reset control ● ● air-cooled reset based on drybulb temp evap-cooled reset based on wetbulb temp ● All single phase motors < 1 hp and < 460 V, either permanent split capacitor or ECM. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 21

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Overview of 2008 T 24 § 126) ( Compressors ● Compressors designed to operate at a minimum condensing temperature ≤ 70 F ● Screw compressor > 50 HP ● Speed control in response to load OR ● Input power ≤ 60% of full load power at 50% of full refrigeration capacity. ● Exception: refrigeration plants with more than one dedicated compressor per suction group 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 22

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Information on 2008 Refrigerated Warehouse Standard ● Classes on 2008 Standard SCE: August 2, CTAC- Irwindale ● Energy Efficiency Hotline ● E-mail: title 24@energy. state. ca. us ● Phone: 916 -654 -5106 or ● Phone: 1 -800 -772 -3300 (toll free in Calif. ) ● Title 24 website www. energy. ca. gov/title 24/ 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 23

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouse 2011 Title 24 Stakeholder Meeting Building Models and Assumptions Brian Dobbs, Va. Com Technologies 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 24

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● Savings calculated with DOE 2. 2 R ● Whole-building/system hourly simulation tool ● Mass-flow based ● Designed for component/control strategy level modeling ● Explicit simulation of most refrigeration control strategies ● Hourly weather file ● Hourly DBT, WBT, wind velocity, solar ● Hourly schedules ● Loads, operations, set-points 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 25

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● DOE 2. 2 R allows detailed simulation of building envelope ● Building constructions ● Define materials and thermal properties ● Calculates roof and wall load ● Accounts for building configuration ● Orientation, adjacent spaces 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 26

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● Details of space definitions ● Simulates infiltration load using: ● ● ● Lighting and lighting controls can be defined Miscellaneous equipment loads can be added ● ● ASHRAE methodology for interzonal air exchange (density difference) Wind velocity adjusted external infiltration Hourly activity schedules Process loads Evaporator fan ● ● Power usage Controls (VFD, fan cycling) 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 27

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● Example of Hourly Schedule Inputs 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 28

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● Detail equipment operation 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 29

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● Energy usage summary and break-outs 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 30

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● Utility usage summary and break-outs 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 31

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Data Analysis Overview ● Initial Analysis: Sacramento weather ● Baseline simulation models: ● Large warehouse (92, 000 ft 2) ● ● R-717 refrigerant ● ● Screw compressors Evaporative-cooled condenser Small warehouse (26, 000 ft 2) ● Semi-hermetic compressors ● R-404 A refrigerant ● Air-cooled condensers 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 32

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Baseline Warehouse Description ● Freezer Space ● ● 40, 000 S. F. (Large Warehouse) 10, 000 S. F. (Small Warehouse) -10°F space temperature R-36 insulation ● Cooler Space ● ● 40, 000 S. F. (Large Warehouse) 10, 000 S. F. (Small Warehouse) 35°F space temperature R-28 Insulation ● Loading Dock ● ● 12, 000 S. F. (Large Warehouse) 6, 000 S. F. (Small Warehouse) 40°F space temperature R-28 insulation 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 33

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Warehouse Diagrams Small Warehouse Large Warehouse 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 34

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Large Warehouse System Description LT Suction Group ● Serves Freezer space ● -23°F design SST ● (2) screw compressors, 62. 5 TR capacity, 165 HP each at design ● Evaporator fan power calculated using 34 Btuh/W spec efficiency ● MT Suction Group ● Serves Cooler and Dock spaces ● 22°F design SST ● (2) screw compressors, 110. 2 TR capacity, 134 HP each at design ● Evaporator fan power calculated using 34 Btuh/W spec efficiency ● Evaporative-cooled Condenser ● 6, 400 MBH capacity at design TD = 23°F (96°F design SCT, 73°F design WBT) ● 330 Btuh/Watt specific efficiency at 100°F SCT, 70°F WBT ● 70°F minimum SCT, wetbulb-following SCT control, variable speed fans working in unison ● 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 35

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Small Warehouse System Description ● Low-Temperature (Freezer) System ● ● ● -23°F design SST, 114°F design SCT (8) Semi-hermetic compressors Air-cooled condensers, 10°F design TD, 53 Btuh/Watt 70°F minimum SCT, drybulb-following control strategy, variable-speed fans Evaporator fan power calculated using 34 Btuh/Watt ● Medium-Temperature (Cooler and Dock) System ● ● ● 22°F design SST, 119°F design SCT (4) Semi-hermetic compressors Air-cooled condenser, 15°F design TD, 53°F Btuh/Watt 70°F minimum SCT, drybulb-following control strategy, variable-speed fans Evaporator fan power calculated using 34 Btuh/Watt 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 36

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Screw Compressor Performance ● Model in large warehouse only ● ● Convert two-compressor suction group to singlecompressor LT and MT system evaluated ● Slide valve part-load performance from manufacturer’s software ● Speed reduction part-load performance from manufacturer’s software ● ● Speed reduction down to minimum speed, then slide valve unloading Analysis includes 3% fixed drive losses 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 37

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Screw Compressor Performance ● Sample Part-load Relation 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 38

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Warehouse Load Description Large Warehouse Small Warehouse Lights 0. 70 Watts/S. F. , all spaces People 1, 500 S. F. , 1, 450 Btuh per person Forklifts 30 forklifts (20 MBH ea), 10 pallet lifts (10 MBH ea), distr. by SF 10 forklifts (20 MBH ea), 3 pallet lifts (10 MBH ea), distr. by SF Product Load Freezer: 400, 000 lb/day, 5°F pulldown, 0. 50 Btuh/(lb °F) specific heat Freezer: 100, 000 lb/day, 5°F pulldown, 0. 50 Btuh/(lb °F) specific heat Cooler: 400, 000 lb/day, 10°F pulldown, 0. 65 Btuh/(lb °F) specific heat PLUS 750 tons respiring product, 5, 500 Btuh/ton heat of respiration Cooler: 100, 000 lb/day, 10°F pulldown, 0. 65 Btuh/(lb °F) specific heat PLUS 188 tons respiring product, 5, 500 Btuh/ton heat of respiration 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 39

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Warehouse Load Description Large Warehouse 4, 000 CFM (200 CFM/dock door, subject to hourly schedule and wind effects). 1, 200 CFM (200 CFM/dock door, subject to hourly schedule and wind effects). Assume inter-zonal doors between Dock and Cooler/Freezer open 15 times per hour each (once every four minutes) Assume inter-zonal door between Cooler and Freezer opens 4 times per hour (once every 15 minutes. Assumed inter-zonal door opening time: 5 seconds to open/close, 15 second stand-open time, 20 seconds total open time per opening Infiltration Small Warehouse Assumed inter-zonal door opening time: 5 seconds to open/close, 15 second stand-open time, 20 seconds total open time per opening 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 40

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Refrigerated Warehouses Building Model and Assumptions Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 41

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouse 2011 Title 24 Stakeholder Meeting 2011 Enhancements of Title 24 for Refrigerated Warehouses Doug Scott, Va. Com Technologies 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 42

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouse 2011 Cycle Title 24 Measures Base Code (2011) ● ● ● Freezer Floor and Roof Insulation R-values Evaporator Specific Efficiency (BTUh/W) Condenser Specific Efficiency (BTUh/W) Ammonia System Air-cooled Condensers Screw Compressor Part-load Performance Acceptance Tests Reach Code ● Condensing Unit EER (BTUh/W) 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 43

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2008 Refrigerated Warehouse Insulation Analysis Summary However, 2008 Standard R-values selected to matched Title 20 Standard for walk-ins 2008 freezer roof and floor: R-36 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 44

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Freezer Roof and Floor Insulation Measures ● Investigate cost-effectiveness of additional freezer roof insulation ● Greater choices for refrigerated warehouses Rvalues than for foamed-in-place walk-in panels ● Investigate cost-effectiveness of R-36 floor insulation vs. a lower level, consistent with standard increment of extruded polystyrene under slab insulation ● Make analysis and requirements consistent in terms of rating temperature (applied temperatures or ~75 F) and new vs. aged 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 45

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Freezer Roof and Floor Insulation Analysis ● Increase freezer roof insulation incrementally from R-36 to ~R-50 ● Decrease freezer floor insulation incrementally from R-36 to ~R-24 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 46

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Freezer Roof and Floor Insulation Data Summary ● Obtain details on common insulation size increments and incremental costs for: ● ● ● Underfloor extruded polystyrene Common over-deck insulation compositions EPS and ISO sandwich roof/ceiling panels. ● Determine assumptions for insulation rating temperature and aged vs. new R-value ● Verify FIP panels can meet requirement ● Identify other constructability issues 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 47

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Freezer Roof and Floor Insulation Data Collection Tasks ● Contact: ● Cold storage construction contractors ● Insulation and panel manufacturers ● GCCA/IACSC (Intl Assn for Cold Storage Const. ) ● Extract information from past new construction projects ● Review requirements in Fed WI Test Standard for testing consistency 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 48

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Freezer Roof and Floor Insulation Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 49

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Code Change Options ● Specific Efficiency = Cooling capacity at a standard rating value divided by power. ● Rating point: 10°F TD between entering air temperature and saturated suction; doesn’t mean this is the applied TD ● Very large range of specific efficiencies. ● High potential savings simply by eliminating the least efficient (high fan power) models, which are not normally used in well engineered systems. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 50

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Code Change Options ● Savings is the improvement from below ● ● ● minimum up to minimum efficiency Easy to justify excluding worst performing models. BUT: This cannot be done properly without test standards and certified ratings for BOTH cooling capacity and power. No evaporators currently state testing to standards and none indicate certification. Requires changes to existing standards. Changes caused by evaporator testing and certification are potentially far-reaching. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 51

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Issues with Ratings ● Evaporator ratings, especially in smaller sizes, generally thought to be significantly commercialized. ● Fan power often not listed, available upon request but may be nominal motor power, not applied power. ● AHRI Standard 420 tests at reasonable conditions but some issues (e. g. freezer coil rated with no frost). 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 52

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Air Circulation Volume, RH, Defrosts ● Air circulation volume and cooling capacity are not generally independent design parameters; airflow usually an unmanaged consequence of coil selection for cooling capacity and price. ● Evaporator are selected to maintain temperature and frequently also humidity; industry has experience-driven practice to achieve proper humidity – typically via coil TD but essentially airflow vs. capacity. ● Industry has experience with TD and FPI (fins per inch) for satisfactory defrosts: which indirectly affects airflow and specific efficiency. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 53

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Analysis and Rating Issues ● Refrigerants and fluids: NH 3, halocarbon, volatile indirect (e. g. ● ● ● ● ● CO 2), single phase indirect (e. g. glycol) Application temperature: two temperatures not enough for rating standards for all application conditions External static pressure: accommodate penthouse coils but not oversized motors or excessive throw Motor loading: define at application conditions Feed type: DX vs. recirculated or flooded Assumptions for wet or dry; frosted or non-frosted coil Assumptions for defrost method and efficiency Fin density: could improve specific efficiency with more FPI but cause excessive defrosts Liquid-suction heat exchanger: may be most cost effective means to increase DX coil performance Refrigerants with glide 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 54

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Summary of Available data ● Savings By Design program history used to establish beginning values: ● Provisional minimum efficiency = 34 BTUh/W ● Average of units purchased in California that were below minimum efficiency = 26 BTUh/W ● Cataloged models put in database ● Evaluate European standards and test methods for evaporators ● Obtain costs from published price lists and sample vendor quotes 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 55

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Data Collection Tasks ● Contacts: ● Evaporator coil manufacturers ● Obtain European standards ● Identify and obtain any available test data to relate catalog data to applied conditions, frosted operation, etc. ● And/or, perform testing in lab (SCE RTTC) or in field, particularly on DX evaporators, possibly along with condensing unit test. ● Request info. from technical advisors 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 56

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Evaporator Specific Efficiency Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 57

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Code Change Options ● Specific Efficiency = Heat rejection capacity at standard rating value divided by power. ● Rating point: 10°F TD between entering air temperature and saturated condensing temperature; doesn’t mean this is the applied TD ● (10°F may be questionable if research determines this is not actually being achieved) ● Midpoint between bubble point and dew point for glide refrigerants ● Very large range of specific efficiencies. ● High potential savings simply by eliminating the least efficient models. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 58

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Code Change Options ● Savings is the improvement from below ● ● minimum up to minimum efficiency. Similar to evaporators, need test standards and certified ratings for both capacity and power. No condenser catalogs currently state testing to standards and none indicate certification. Requires changes to existing standards. Changes caused by condenser testing and certification are potentially far-reaching. ● ● Air cooled: affects other applications such as supermarket condensers Evap cooled: affects many industrial applications 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 59

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Issues with. Evap -Cooled Ratings ● Wide range of types: ● ● Forced draft, induced draft Indoor location with external static ● Standards: ● ASHRAE Standard updated in 2005 (methods) ● AHRI test points: 78°F WBT and 105°F SCT (R-22) and 96°F (NH 3) – WBT is far from normal range. Relies on manufacturers application correction factors. ● Cooling Tower Institute not yet investigated. ● High cost of testing and rating ● Variable speed changes low power economics 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 60

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Issues with Air-Cooled Ratings ● Air cooled capacity historically shown with a single Q=UATD from 1 to 30°F TD. ● ● AHRI Standard based on 30°F TD standard test point vs. 10°F and 15°F commercial application (Not saying AHRI Standard is being used) ● Fan power often not listed, OEM motors, power available upon request but may be nominal motor power, not applied power. ● New product changes: BLDC motors (variable speed; variable specific efficiency by setting max speed); micro channel HX. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 61

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Issues with Air-Cooled Ratings ● Test ratings at high SCT may not fairly compare operation at (more common) reduced head pressure due to internal pressure drop at reduced pressure. ● European standards may give guidance on defining performance for application conditions. ● Variable speed changes economics of low power condensers. ● Most of year is not at reduced speed; third power fan power reduction. Longer payback for larger and/or low power condenser. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 62

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Summary of Available data ● Savings By Design program history used to establish beginning values: ● Provisional minimum specific efficiency: ● ● ● Evap: 330 BTUh/W at 100°F SCT, 70°F WBT Air: 53 BTUh/W at 10°F TD Average of units purchased in California that were below minimum efficiency: ● ● Evap: 220 BTUh/W Air: 44 BTUh/W ● Most cataloged models have been databased ● Evaluate European standards and test methods ● Obtain costs from published price lists, pricing software and sample vendor quotes 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 63

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Data Collection Tasks ● Contacts: ● Condenser manufacturers ● Obtain European standards ● Identify and obtain any available test data: ● Air-cooled, in particular 30°F vs. 10°F TD ● Evap-cooled, in particular information on correction factors related to test/standard basis ● Request info. from technical advisors. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 64

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Condenser Specific Efficiency Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 65

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Air-Cooled Ammonia Condenser Code Change Options ● Allow use of air-cooled condensers on ammonia systems. ● Potential benefits: ● ● ● Ammonia air-cooled systems with T 24 sizing and control may have comparable annual k. Wh as evap-cooled in many regions (Air-cooled has higher peak k. W. ) Water savings – important in California Energy savings with ammonia (if air is going to be used anyway) 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 66

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Air-Cooled Ammonia Condenser Analysis Issues ● Evaluate a cost-effective minimum specific efficiency; probably different than halocarbon condensers. ● Include specific efficiency requirement and existing VFD requirement. ● Utilize existing mandatory sizing requirements of 10°F (low temp) and 15°F (med temp). ● Calculate water savings. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 67

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Air-Cooled Ammonia Condenser Data Collection Tasks ● Obtain information from ammonia air-cooled condenser manufacturers (there are two or more). ● Obtain price quotes. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 68

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Air-Cooled Ammonia Condenser Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 69

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Compressor Part Load Efficiency Code Change Options ● Change: Simplify 2008 screw compressor variable speed requirement and/or the exemption via part-load efficiency. ● Issue: Industrial screw compressor ratings are generally not published in accordance with a rating standard and are not certified, at either full load or for part load performance. ● Possible change to mandatory application- based criteria, eliminating compressor part-load efficiency as a basis of compliance. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 70

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Compressor Part Load Efficiency Analysis ● Simulation analysis to determine: ● Threshold saturated suction temperature below which variable speed is consistently cost effective for single stage compressors. ● Whether variable speed for booster compressors (on two stage systems) is cost effective. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 71

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Compressor Part Load Efficiency Summary of Available data ● Utilize existing manufacturers performance software. ● Obtain additional lab test information as available from manufacturers. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 72

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Compressor Part Load Efficiency Data Collection Tasks ● Obtain costs from compressor manufacturers price lists, price quotes and from VFD vendors. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 73

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Compressor Part-Load Efficiency Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 74

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Reach Code Option Air-Cooled Condensing Unit EER ● 2008 Code exempts most unitary air-cooled condensing units from condenser sizing (TD) requirement. Large air-cooled units ARE required to meet TD, but problematic for “catalog” units since the application conditions are not known when designed. ● EER (Energy Efficiency Ratio) is cooling capacity divided by input power of the entire condensing unit (compressor and condenser fan energy). ● EER and (usually) power are not published and capacity is generally thought to be based on compressor ratings not unitary test standards. ● 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 75

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Reach Code Option Air-Cooled Condensing Unit EER ● Condensing unit capacity based on compressor standard ratings inherits a large and long standing error: ● ● ● Most refrigeration compressor are rated at a fixed 65°F RGT (return gas temperature) regardless of saturated suction. All superheat from evaporator temperature to 65°F is assumed to be productive refrigeration. Potential error between catalog capacity and actual productive refrigeration can be 15 -35%. ● Test data lacking on: ● Actual productive cooling capacity vs. unit rating ● Compressor performance at varying RGT 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 76

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Reach Code Option Air-Cooled Condensing Unit EER ● EER standards must be done in parallel with evaporator standards, to avoid causing a mismatch. ● Capacity shortfall probably masked by rule-ofthumb load calculations and adjustment for “ 18 hour” run times. If system capacity ratings decrease, equipment will be larger than before and with less run time. Training needed to select equipment properly under new ratings. ● EER standards would likely cause all catalogs to change, impacting other uses. ● Compressor manufacturers will need to provide rating data or adjustments for lower RGTs. 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 77

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Reach Code Option Air-Cooled Condensing Unit EER Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 78

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouse 2011 Title 24 Stakeholder Meeting Acceptance Tests Michele Friedrich, PECI 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 79

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Acceptance Tests ● What are acceptance tests? ● Tests performed on the building’s systems in order to show compliance with the code. ● When are acceptance tests implemented? ● After start-up ● Before normal use of the equipment ● Who can do the acceptance tests? ● Licensed mechanical engineer, civil engineer, architect or contractor 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 80

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM Refrigerated Warehouses Acceptance Tests How to show Compliance? ● Checklist ● Certificate of acceptance ● Submittal of necessary documentation 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 81

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Acceptance Tests Development Process 1. Post installation verification site visits 2. Develop preliminary version or tests 3. Pilot test the tests Solicit input from stakeholders 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 82

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Acceptance Tests Acceptance Requirements for 2008 Code ● Electric Resistance Underslab. Heating ● Evaporator Fans ● Evaporative-cooled Condenser Fans ● Air-cooled Condenser Fans ● Screw Compressors 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 83

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Acceptance Tests Comments? Questions? 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 84

CALIFORNIASTATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2011 Acceptance Tests Wrap Up Michele Friedrich, PECI 2011 Refrigerated Warehouse Stakeholder Meeting 04/15/2010 85