RFMA 2016 Annual Conference March 13‐15, 2016
Innovative
Technology
Drives Real
Results
Curt Sawan – Red Lobster
Greg DuChane – Trane
Steve Brown - LC Systems
Presenter Introductions
• Curt Sawan – Red Lobster
• Facility Manager
• ASHRAE TC 5.10 Member
• Greg DuChane ‐ Trane
• Director, Retail / Restaurant National Accounts
• ASHRAE TC 5.10 Past Chair
• ASHRAE RP‐1469 “Comfort Commercial Kitchens” Chair
• Steve Brown – LC Systems
• President, LC Systems
• ASHRAE TC 5.10 Past Chair
What are We going to Learn
Today?
Curt Sawan
• Results of Application & Testing of New Variable Speed Rooftop Unit Technology to Control Temperature, Humidity & Measure Power Consumption Vs. a Traditional High Efficiency Rooftop Unit with Hot Gas Reheat (Dehumidification) on an existing Red Lobster Dining Room in Clarksville, IN (Louisville, KY Area)
• New Hood Airflow Testing Procedure
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – Clarksville, IN
Background & HVAC Issues
• History of Red Lobster Restaurant – Clarksville, IN
Building Design (Dining ‐ 40 Tons Total)
1.
2.
3.
Three Dining Room Rooftop Units (15, 15 & 10 Ton)
Single Thermostat per Rooftop Unit
Sequential Compressor Staging
Inherent Issues
1.
2.
3.
Inadequate Compressor Run Times ‐ Oversized
Coverage Area Too Large for Single Thermostat
Outdoor Air Introduction during Normal Operation
Standard Unit Short Cycling
Red Lobster – Clarksville, IN
Background & HVAC Issues
• Problems Encountered
Guest Comfort
High Humidity
Mold
Employee discomfort
Building Air Balance (Negative Pressure)
Red Lobster – Moisture Issues
High Indoor Relative Humidity
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – Moisture Issues
High Indoor Relative Humidity
Red Lobster – Clarksville, IN
HVAC Design Layout
• Past Experiences
Kitchen
Other buildings with same design
15 Ton
Current equipment‐
asset cost and design
10 Ton
Unit
AgeUnit
Lobby
Sizing
Raised Deck
Ability to perform as needed
10 Ton
Humidity Control Unit
15 Ton Main Dining 15 Ton
Energy efficiency
Unit
Unit
Implication for future retrofits
Ductwork
Remodels
Red Lobster – Clarksville, IN
Total Outside Air
Building Pressure: +619 CFM
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – Clarksville, IN
Moisture in Outdoor Air
• Outdoor Design ‐ 91 F DB / 79 F WB = 131 grains
• Indoor Design – 75 F DB / 50% RH = 64 grains
• To Achieve Comfort ‐ We must Remove 67 grains (131 – 64) of Moisture from of the outdoor air! F DB
F WB RH Dry Bulb Temperature (F)
Wet Bulb Temperature (F)
Relative Humidity (%)
Red Lobster – Clarksville, IN
Facts of Moisture in Outdoor Air
• 1 lb. of water = 7,000 grains • 1 cfm = 4.5 lbs air / hour
• 1 gallon water = 8.33 lbs
So for 1,000 cfm…
=1000 cfm x 4.5 lbs air/hr X 131 gr/lb = 589,000 gr/hr
= 589,000 gr/hr / 7000 gr/lb = 84.2 lbs water/hr = 84.2 lbs water/hr / 8.33 lb/gal = 10.1 gal/hr total water content
lbs/hr water removed = 4.5 X cfm X grains removed (gr/lb) / 7000 gr/lb
= 4.5 X 1000 cfm X (131‐64)/7000
= 43.1 lbs/hr
gal/hr = 43.1 lbs/hr / 8.33 lb/gal
5.2 Gallons per Hour!
Red Lobster – Clarksville, IN
Outdoor Air Management
•
•
•
•
•
10,500 CFM outdoor air
1,000 CFM Outdoor Air = 5.2 gallons per hour
HVAC System must Manage 54.6 Gallons per Hour
Exhaust Hood / Make‐Up Air, HVAC Units, etc.
10 tons of HVAC units Running at Full Capacity & Making 55 F Air will Remove 5 gallons of water per hour
• So the 60 Tons of HVAC Units running at full capacity will remove 30 gallons per hour.
• What happens to the other 20 gallons?
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RFMA 2016 Annual Conference March 13‐15, 2016
Considerations for resolution
• Hood operations & Performance
• Restaurant Operations
• RTU Dehumidification Options available
• Past & Present
Retrofit current equipment ‐ APR Device
Add Dehumidifier(s)
Hot Gas Reheat
Other Options?
What about energy efficiency?
• Must be another option?
• Future energy consumption & Green Buildings
• What new technology is out there to reduce energy but still get results?
New Technology Introduction
Greg DuChane
• Variable Speed Rooftop Unit Technology
• Variable – Variable – Variable (V3)
• Compressor
• Supply or Indoor Fan
• Condenser Fan
• Integration into Package Rooftop Units
• What do they do & how do they work?
• HVAC Design Considerations
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – HVAC Test Layout
10 Ton
High
HGRH
(New)
15 Ton
High
V3
(New)
15 Ton
Standard
(Existing)
Red Lobster - Data Acquisition
• Temperature & RH Control
• 3 – Dining RTU’s
• 2 ‐ Kitchen RTU’s
• Dining & Kitchen RTU Power
• Exhaust & Supply Fan Power
• Main Building Power
• Power Monitoring Station
• Wireless Temperature / RH Control
• User Interface (Color Display)
• Cell Router / Modem
Red Lobster – October Results
Part Load Days & Temperature Variance
Night ‐ Unoccupied
Night ‐ Cleaning
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – System Status
Dining Area Occupied Dashboard
Red Lobster – Guest Comfort
Outdoor Air Temp: 60 – 85 F
72 F
35%
OCCUPIED
OCCUPIED
OCCUPIED
Variable Speed – T:
Hot Gas Reheat – T:
Std. Efficiency – T:
72 F Avg. (74 – 68 F Range)
72 F Avg. (74 – 70 F Range)
72 F Avg. (74 – 70 F Range)
Variable Speed – RH:
Hot Gas Reheat – RH:
Std. Efficiency – RH:
40% Avg. (55 – 30% Range)
35% Avg. (50 – 30 % Range)
45% Avg. (50 – 30% Range)
Red Lobster – Guest Comfort
Observations
• Hot Gas Reheat (Active Dehumidification)
• Tightest Temperature & RH Control
• Traditional Energy Penalty
+1/3 More Power or Greater on Average
• Variable Speed Fan & Outdoor Air Compensation offer Very Good Temperature & RH Control within Acceptable Temperature ‐ RH Limits & offers Substantial Energy Savings Opportunity
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – Guest Comfort
Issues & Head Winds
• Dining Area Variable Speed & Hot Gas Reheat Unit Overcome RH Issues in Dining Area Served by Standard Efficiency Unit with Dehumidification due to Vapor Pressure Equalization
• Unconditioned Kitchen Make‐Up Air Adds Moisture to Dining Area due to Vapor Pressure Equalization – Internally Compensating or Short Circuit Hoods
• Existing Dining Area Rooftop Unit is Short‐Cycling & Loading the Dining Area with “Off Cycle” Humid Outdoor Air Creating a Moisture Load for the Hot Gas Reheat & Variable Speed Compressor Units
Variable Speed Technology
Compressor, Indoor Fan & Condenser
Fan
Benefits of Variable Speed
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – System Status
Dining Area Occupied Dashboard
Variable Speed Vs. HGRH
Red Lobster – Clarksville, IN
Heat Map & Scatter Plot
• Heat Map Identifies Energy Usage Intensity by Day by Hour
• Scatter Plot Identifies Energy Usage
• HGRH – High Usage
• VS – Wide Operating Range
Red Lobster – Clarksville, IN
Dining Area Load & Energy Calculations
October Actual EMS
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RFMA 2016 Annual Conference March 13‐15, 2016
Red Lobster – Clarksville, IN
3 RTU – 12.5 Ton – Dining Roof Sweep
Problem Statement
Restaurant was Experiencing
High Humidity & Difficulty
Controlling Building Moisture
2.1 Years
Var. Speed
Problem Solution
Rooftop HVAC Units with Hot
Gas Reheat or Variable Speed
Results
Variable Speed Rooftop Units
Provide 2.1 Year Payback Saving Energy & Providing
Comfort & Humidity Control
Alt. 1: High Efficiency
Atl. 2: High Eff. – Hot Gas Reheat
Alt. 3: High Eff. – Variable Speed
Red Lobster – Clarksville, IN
Lessons Learned
• Don’t Assume that Replacing “Like for Like” Rooftop HVAC Units will Solve the Problem –
Recommend 3 – 12.5 Ton HVAC Units (37.5 Tons Vs. 40 Tons Originally)
• HVAC Loads Change Over Time – Lighting Upgrades, Seating Configurations & Actual Restaurant Volume / Loads Change
• Take Time & Perform Load & Energy Calculations Prior to Recommending a Replacement Strategy
• Hot Gas Reheat & Variable Speed Rooftop HVAC Systems Can Provide Superior Temperature & Humidity Control BUT Look for other Sources of Unconditioned Outdoor Air Loads –
Compensating Hoods & Make‐Up Air in the Red Lobster – Clarksville, IN
Live Data
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RFMA 2016 Annual Conference March 13‐15, 2016
Tricks of the Trade
Yes…We are Geeks!
Temperature & RH
Data Logging
Airflow Measurement
Smart Phone Interface
Pocket Temperature & RH Sensor
Questions?
Curt Sawan – Red Lobster
Facility Manager
Greg DuChane – Trane
Retail‐Restaurant National Accounts
Presenter Introductions
Airflow Testing Method of Test Update
• Steve Brown – LCSystems
• President, LCSystems, Inc.
• ASHRAE TC 5.10 Past Chair
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RFMA 2016 Annual Conference March 13‐15, 2016
TAB Ports - CKV Air Balance
RELIABLE - ACCURATE - EASY
KVE-10
2001.02
T.A.B. Test & Balance Ports
0.50
0.30
p st
[''WC]
0.20
0.10
1000
2000
3000
qv [cfm]
EASE OF BALANCING. FIELD SYSTEM FOR BALANCING AIR FLOW RATES
ASHRAE Research
MOT Evaluate Field Performance of CKV Systems
4" RVA Cold Discrete
Cyclone Filter Results
4000
4" RVA Cold Traverse
2.75" RVA Cold Discrete
3500
2.75" RVA Cold Traverse
Qmeasure (SCFM)
Hot Film Cold Discrete
3000
Hot Film Cold Traverse
Velocity Grid Cold
2500
Flow Hood (2'x4') Cold
Flow Hood (2'x2') Cold
2000
4" RVA Hot Discrete
4" RVA Hot Traverse
1500
2.75" RVA Hot Discrete
2.75" RVA Hot Traverse
1000
Hot Film Hot Discrete
500
Hot Film Hot Traverse
Velocity Grid Hot
0
Flow Hood (2'x4') Hot
0
1000
2000
3000
4000
Qactual (SCFM)
Flow Hood (2'x2') Hot
K-factor of 1
Most Hand‐Held Devices Report Exhaust Readings are LOW!
ASHRAE Research
MOT Evaluate Field Performance of CKV Systems
Perimeter Results
3500
4'' RVA Cold Discrete
4" RVA Cold Traverse
3000
2.75" RVA Cold Discrete
2.75" RVA Cold Travers e
Hot Film Cold Discrete
2500
Qmeasured
Hot Film Cold Traverse
Velocity Grid Cold
2000
4" RVA Hot Discrete
4" RVA Hot Traverse
1500
2.75" RVA Hot Dis crete
2.75" RVA Hot Traverse
1000
Velocity Grid Hot
Hot Film Hot Discrete
500
Hot Film Hot Traverse
K Factor of 1
2'x2' FlowHood Cold
0
0
500
1000
1500
2000
2500
2'x2' FlowHood Hot
Qactual
Most Hand‐Held Devices Report Supply Readings that are HIGH!
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RFMA 2016 Annual Conference March 13‐15, 2016
ASHRAE Research
TAB Pressure Convenient - Reliable
TAB Pressure Readings are HIGHLY ACCURATE! Hand Held Readings Off by Just 10%
Results in 90% Increase in Building Outdoor Airflow
4400
4500
4000
4000
3600
3500
3520
3200
3000
2880
Exhaust
2500
MUA
2000
1520
1500
Building
1040
800
1000
500
0
Design
Hand Held Reading
Field Adjusted
Exhaust Read 10% Under Design & MUA Read 10% Over Design Field Adjusted =
Building Supply 90% over design!
Conclusions
Hood and Fan Pressure TAB Ports • Easy to Use
• High Degree of Air Balancing Accuracy
• Customer tool • Maintenance Check
• Performance Update
• Require Manufacturer’s Certification 13
RFMA 2016 Annual Conference March 13‐15, 2016
Questions?
Steve Brown – LC Systems
President
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