Harley-Davidson Museum
Milwaukee, WI.
Jonathan Rumbaugh, BAE/MAE
Mechanical Option
Advisor: Dr. William Bahnfleth
PROJECT SPONSORS
PRESENTATION OUTLINE
•
•
•
•
Project Background
Existing Conditions
Thesis Goals
Depth One
• Thermal Bridging
• Depth Two
• Heat Rejection
• Cooling Tower
• River Water
• Depth Three
• CHP Feasibility
• Conclusions
BUILDING STATISTICS
•
Size (Total Square Feet): 130,000
•
Number Stories Above grade: 3
•
Construction timeline : April 2005 – May 2008
•
Overall Project Cost: $75 million
LOCATION & LAYOUT
LOCATION & LAYOUT
LOCATION & LAYOUT
LOCATION & LAYOUT
LOCATION & LAYOUT
MECHANICAL DESIGN
•
Two Roof Mounted 300 Ton Air-cooled Rotary Screw Chillers
•
Four 2000 MBH Sealed Combustion Condensing Boilers
•
Variable Primary Flow
•
11 Air Handling Units
2
4
5
ENERGY MODEL
Peak Cooling Plant Loads
Peak Heating Plant Loads
Desgin TRACE MODEL Design to Model
Desgin TRACE MODEL Design to Model
ton
ton
600
585.3
%Δ
-2%
Total Building Energy [kBtu/yr]
MBh
MBh
8000
9073
%Δ
13%
Total Source Energy [kBtu/yr]
Primary Heating
10%
Receptacle
15%
Primary
Heating
24%
Primary
Cooling
14%
Lighting
33%
Auxiliary
14%
Receptacle
17%
Lighting
40%
Primary
Cooling
16%
Auxiliary
17%
ENERGY MODEL
$0.10 / kWh Electricity
$0.80 / Therm Natural Gas
Annual Cost Breakdown
6%
18%
Cost Breakdown
17%
Primary Heating
Primary Cooling
Auxiliary
18%
41%
Lighting
Receptacle
Cost
Primary Heating
Primary Cooling
Auxiliary
Lighting
Receptacle
Total
$ 20,252.00
$ 62,223.50
$ 64,463.40
$ 150,907.60
$ 65,906.60
$ 363,753.10
EMISSIONS
1.00E+07
9.00E+06
8.00E+06
7.00E+06
6.00E+06
5.00E+06
4.00E+06
3.00E+06
2.00E+06
1.00E+06
0.00E+00
Precombustion
Natural Gas
Calculations use factors from the
Regional Grid emissions Factors 2007.
table B-10
VOC
Solid Waste
Emissions With Actual Natural Gas Values: No CO2
4.50E+04
4.00E+04
Mass of Pollutant (lb)
Pollutant
PM10
Mercury
Lead
TNMOC
CO
SOx
NOx
N2O
CH4
CO2
Electric
CO2e
Mass of Pollutant (lb)
Emissions With Actual Natural Gas Values
3.50E+04
3.00E+04
2.50E+04
2.00E+04
Precombustion
1.50E+04
Natural Gas
1.00E+04
Electric
5.00E+03
0.00E+00
Pollutant
EMISSIONS
9 Million lbs. of C02e / year
867 acres
COMPARISON
500,000
120
450,000
110
400,000
100
350,000
90
300,000
80
250,000
70
200,000
60
2010 kWh
2010 kWh
TRACE KWH
150,000
100,000
2010 Temp
2010 Temp
TRACE temp
50,000
0
50
40
30
20
Date
Temp
Kilowatt Hours (kWh)
Museum Campus Electricity Use
GOALS
• Reduce Emissions
• Reduce Energy Consumption
• Reduce Operating Cost
Energy
Consumption
Operating
Cost
Emissions
PROPOSAL
• Decrease Thermal Loads Through Envelope
• Increase Efficiency of Chilled Water
Production
• Become Energy Independent From Grid
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
Location of thermal break
N
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
T1
T2
BRIDGING
DEPTH ONE THERMAL
8760 hr. study
Total: 108.19 Watts per year
Lowest indoor temp = 69 oF
Savings: $1,271.19 / year [Main gallery]
For a simple payback of 5 years
Each Thermal Break = $653
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH ONE THERMAL
BRIDGING
DEPTH TWO HEAT
Two 300 Ton Air Cooled Chillers
EER 9.4
Carrier
REJECTION
DEPTH TWO HEAT
Carrier
REJECTION
DEPTH TWO HEAT
Two 300 Ton Water Cooled Chillers
COP 5.9
EPA
REJECTION
DEPTH TWO HEAT
REJECTION
DEPTH TWO HEAT
REJECTION
CAPITAL
Alternative 1: Air- Cooled
Equipment
Alternative 2: Water-Cooled
Price
AC Chiller 1 $215,000.00
AC Chiller 2 $215,000.00
Equipment
WC Chiller 1
WC Chiller 2
Price
$ 140,500.00
$ 140,500.00
Cooling Tower 1 $ 37,000.00
Cooling Tower 2 $ 37,000.00
CW Pump 1
CW Pump 2
$
$
5,575.00
5,575.00
CW Piping
$ 21,000.00
4 Boilers
$ 120,000.00
4 Boilers
$ 120,000.00
Total
$ 550,000.00
Total
$ 507,150.00
Additional Water: 2,500 1000gal
Cost : $5,500.00 / year
Capital: -$42,850
DEPTH TWO HEAT
30 Year LCC
Existing Air-Cooled System: $4,045,288.09
Alternative 2; Water-Cooled System: $3,861,471.04
Savings: $183,817.05
*Total CO2e (lb):
Air-Cooled
Water-Cooled
% Diff
9.01E+06
8.77E+06
3%
REJECTION
DEPTH TWO HEAT
Supply
Return
REJECTION
DEPTH TWO HEAT
REJECTION
DEPTH TWO HEAT
Cold Water Temp = 0.739*WB + 27.35
REJECTION
DEPTH TWO HEAT
REJECTION
DEPTH TWO HEAT
REJECTION
DEPTH TWO HEAT
REJECTION
DEPTH TWO HEAT
REJECTION
CAPITAL
Alternative 2: Water-Cooled
Cooling Tower
Equipment
Price
WC Chiller 1
WC Chiller 2
$ 140,500.00
$ 140,500.00
Cooling Tower 1 $ 37,000.00
Cooling Tower 2 $ 37,000.00
5,575.00
5,575.00
Alternative 3: Water-Cooled
River Water
Equipment
Price
WC Chiller 1
WC Chiller 2
$ 140,500.00
$ 140,500.00
River Pump 1
River Pump 2
River Piping
Heat Exchanger
Filtration System
$ 12,000.00
$ 12,000.00
$ 52,500.00
$ 18,000.00
$ 100,000.00
CW Pump 1
CW Pump 2
$
$
5,575.00
5,575.00
4,750.00
CW Pump 1
CW Pump 2
$
$
CW Piping
$ 20,995.00
CW Piping
$
4 Boilers
$ 120,000.00
4 Boilers
$ 120,000.00
Total
$ 507,145.00
Capital: +$104,255
$ 611,400.00
DEPTH TWO HEAT
REJECTION
Simple Payback:
2.8 years
Discount payback : 3.0 years
30 Year LCC
Alternative 2; Cooling Tower System: $3,861,471.04
Alternative 3; River Water System: $3,641,264.61
Savings: $220,206.43
*Total CO2e (lb):
Alt 2: Cooling Tower
Alt 3: River Water
% Diff
8.77E+06
8.57E+06
2%
DEPTH TWO HEAT
REJECTION
DEPTH TWO HEAT
REJECTION
Air-Cooled vs. Water-Cooled with River Water
• Capital cost increased 10% [$61,400.00]
• Annual operating cost reduced by 14% [$21,732.00]
• 30 year LCC reduced 10% [$389,986.00]
• Simple payback 3 years
DEPTH THREE CHP
FEASIBILITY
DEPTH THREE CHP
FEASIBILITY
Spark Gap
Electric Cost: $0.10/kWh = $29.30/MMBTU
Gas Cost: : $0.80/therm = $8.00/MMBTU
1 : 3.7 Ratio , 1 : 4 [rule of thumb]
DEPTH THREECHP
Thermal-to-Electric Ratio = 0.74
Recommended: 373 kWe Gas Engine
FEASIBILITY
DEPTH THREE CHP
Conclusions
• Additional Cost $564,000
• Generation Cost $0.088 /kWh
1.2 cents less than purchased
• Total Savings: $140,000 /year
• Simple Payback: 4.04 Years
• CO2 reduction of 62%
FEASIBILITY
RECOMMENDATIONS
+
=
+
Total
• $160,000 Annually
• 4 Year Payback
• 65% Reduction of CO2
QUESTIONS?
DEPTH ONE THERMAL
Member
Force
Allowable
Actual
OK?
Beam
Bending
Moment
64.12 ft
kips
18.5 ft kips Yes
Beam
Shear
79.1 kips
3.7 kips
Girder
Bending
Moment
3723 ft kips 686 ft kips
Yes
Girder
Shear
886 kips
40.05 kips
Yes
Girder
Live Load 3.4”
Deflection
2.75”
Yes
Girder
Total
6.85”
Deflection
6.6”
Yes
Column
Load
355 kips
50 kips
Yes
Thermal
Break
Shear
13,400 psi
2.24 psi
Yes
Yes
BRIDGING