Evaporator Fan Motor Controller (ECM) for Walk

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Today’s “Game Plan”

Two Trial-Runs of a new deemed measure review process

– Deemed measure analysis and review

• Developed by …

– (consultant, RTF member/staff, utility, etc.)

• Reviewed in detail by RTF subcommittee

– Until comfort level is high

– RTF Staff* gives a summary presentation to the full RTF

• Summary of subcommittee review

– Including details of any follow-up that hasn’t been fully vetted by the subcommittee

• Summary of the measure analysis

– Energy savings analysis presented using the (draft) measure summary template

– Measure Cost, Measure Life, O&M, etc.

The Goals

– Improve and add consistency to the deemed measure review process

– Spend less time “in the weeds” at RTF meetings

*with support from both the subcommittee and the measure analysis developer

3

LED Lighting in Vertical and Semi-Vertical

Open Display Cases

Deemed Measure Proposal

Regional Technical Forum

September 28, 2010

Analysis Prepared By:

RTF Subcommittee Review?

RTF Staff Review?

Presentation Prepared By:

PECI (Eric Mullendore and

Michele Friedrich)

Yes (Sept 2, 2010)

Yes (Adam Hadley)

RTF Staff (Adam Hadley)

Measure Description

• Measures

– Existing Cases

• Remove T8, T10, or T12 Fixtures and Ballasts, install LED fixtures and drivers

– 1-lamp Fluorescent fixture  1 Low-power LED fixture

– 2-lamp Fluorescent fixture  1 High-power LED fixture

– 3-lamp Fluorescent fixture  1 High-power LED fixture + “delamp” measure

– New Cases

• Choose LED fixtures instead of T8 fixtures

– 1 Low-power LED fixture (baseline = 1-lamp T8 fixture)

– 1 High-power LED fixture (baseline = 2-lamp T8 fixture)

• Savings

– Reduced energy use of lighting system

– Reduced load on the refrigeration system

• Requirements

– This measure only applies to open vertical or semi-vertical display cases.

• (does not apply to coffin cases)

– Fluorescent fixture and ballast must be replaced with a permanently installed LED fixture and driver

– LED ratings: Minimum CRI of 75; minimum of 7% of initial lumens at 50k hours.

– Minimum 3-year manufacturer’s warranty.

– Delamp measure must be combined with an LED retrofit measure

– Baseline controls, or better, must be used

5

Subcommittee Review

Meeting held September 2, 2010

(meeting notes available at: http://www.nwcouncil.org/rtf/subcommittees/grocery/meetings/meetings.htm

)

– Attendees

• PECI: Lagan Todd, Jen Shafter, Dustin Bailey, Ben Cartwright, Paul Schertz, Ben Wright,

Michele Friedrich

• RTF/Other: Diwanshu Shekhar, Charlie Grist, Eric Brateng, Tim Steele, Adam Hadley,

David Baylon

Meeting Summary:

– PECI generated the analysis and presented its proposal to the subcommittee

– The group reviewed key input parameters and supporting data sources in detail

– Conclusion: PECI’s savings calculation approach and input assumptions are reasonable. The only follow-up needed is review of the assumption on number of ballasts per lamp.

Meeting Follow-up (not reviewed by subcommittee):

– Ballasts/drivers per lamp is not addressed directly. The calculation determines energy use of the ballast/driver based on a fixed percentage of the lamp power draw.

6

Summary of Methdology and Sources for Unit Energy Savings Estimate (Continued)

Measure Classification and Properties

Market Sector Commercial

New / Existing Existing and New

Market Segment

Measure Category

RTF Workbook:

Grocery

LED Case Lighting

Grocery_EvaporatorFanControllerECMWalkIn_FY10v1_0.xls

Number of Measures, and UES

Components 8 measures with 2 UES components each

Measure Identifiers

Identifier

Baseline Lamp Type

LED Fixture Power (baseline number of lamps in fixture)

De-lamp

Possible Values

Existing T8

Existing T12 or T10

New Construction

High Power LED Fixture (baseline: 2-lamp fixture)

Low Power LED Fixture (baseline: 1-lamp fixture)

De-lamp

Further Explanation and Sources

Does not apply to new construction.

LED fixture power is not relevant.

Constant Parameters

Parameter

Hours of Operation

Hours of Operation Weighting

Portion of lamp energy rejected to the refrigerated space

Lamp location weighting (Applies to low power only)

Possible Values

18 hours per day

24 hours per day

18 hours per day: 49%

24 hours per day: 51%

Shelf: 100% (Applies to low power only)

Canopy or Rail: 50% (Applies to high or low power)

Shelf: 49%

Canopy or Rail: 51%

Further Explanation and Sources

Assumed

PECI invoice data for 1000 feet of medium temperature display cases

DOE: Final Rule for Commercial Refrigeration

Equipment

PECI audit data for 398 1-lamp fixtures in open cases in multiple stores in the PNW

7

Summary of Methdology and Sources for Unit Energy Savings Estimate (Continued)

Unit Energy Savings (UES) Estimation Method, Parameters and Sources

Measure Type UES

Component

Analysis approach Primary

Parameter /

Adjustment

Factor

Direct lighting energy savings

Baseline

Description

Savings is calculated as the difference between the energy use of the baseline and replacement lighting system. Energy use of the lighting systems is calculated as the sum of the lamp energy use and ballast (driver) energy use.

Lamp and ballast (driver) energy use are both calculated by the product of their hours of operation and their power draw. Savings are calculated for two hours of operation scenarios and weighted.

Lamp Power

Use (per linear foot)

Ballast/Driver

Power Use

T-8

1-lamp: 8 watts

2-lamp: 16 watts

T-12/10

1-lamp: 10 watts

2-lamp: 20 watts

T-8: 5% of fixture power

T-12/10: 15% of fixture power

Replace fluorescent fixture in open display cases with LED fixture

Refrigeration system savings due to reduced heat load from direct lighting energy savings

The approach applies the EER of the refrigeration system to the portion of direct lamp energy savings that would have been rejected to the refrigerated space.

Portion of lamp energy rejected to the refrigerated space is based on lamp location within the case.

Savings are calculated for two hours of operation scenarios and weighted. For 1-lamp fixture baseline measures, savings are also calculated for two lamp location scenarios and weighted.

EER 10.9

Efficient

Case

Description

High Power

7 watts

Low Power

4 watts

10% of fixture power

Baseline Source Efficient Case

Source

Grainger Catalog

32W T8

40W T12

Grainger Catalog

DOE2.2R Model from GrocerSmart

3.0

Manufacturers'

Specifications

Manufacturers'

Specifications

8

Summary of Methdology and Sources for Unit Energy Savings Estimate (Continued)

Unit Energy Savings (UES) Estimation Method, Parameters and Sources

Measure Type UES

Component

Analysis approach Primary

Parameter /

Adjustment

Factor

"Delamp" occurring during replacement of

3-lamp fluorescent fixture in open display cases with a highpower LED fixture

Direct lighting energy savings

Refrigeration system savings due to reduced heat load from direct lighting energy savings

Savings is calculated as the sum of lamp energy use and ballast energy use of 1 lamp in a 3-lamp fixture. Lamp and ballast energy use are both calculated by the product of their hours of operation and their power draw. Savings are calculated for two hours of operation scenarios and weighted.

The approach applies the EER of the refrigeration system to the portion of direct lamp energy savings that would have been rejected to the refrigerated space.

Portion of lamp energy rejected to the refrigerated space is based on a canopy or rail location. Savings are calculated for two hours of operation scenarios and weighted.

Lamp Power

Use (per linear foot)

T-8

1-lamp: 8 watts

2-lamp: 16 watts

T-12/10

1-lamp: 10 watts

2-lamp: 20 watts

T-8: 5% of fixture power

Ballast/Driver

Power Use

T-12/10: 15% of fixture power

EER

Baseline

Description

10.9

Efficient

Case

Description

High Power

7 watts

Low Power

4 watts

10% of fixture power

Baseline Source Efficient Case

Source

Grainger Catalog

32W T8

40W T12

Grainger Catalog

Manufacturers'

Specifications

DOE2.2R Model from GrocerSmart

3.0

Manufacturers'

Specifications

9

Summary of Methdology and Sources for Unit Energy Savings Estimate (Continued)

Measure Type UES

Component

Direct lighting energy savings

Analysis approach Primary

Parameter /

Adjustment

Factor

Baseline

Description

Efficient

Case

Description

Baseline Source Efficient Case

Savings is calculated as the difference between the energy use of the baseline and replacement lighting system. Energy use of the

Lamp Power

Use (per linear foot) lighting systems is calculated as the sum of the lamp energy use and ballast (driver) energy use.

Lamp and ballast (driver) energy use are both calculated by the product of their hours of operation and their power draw. Savings are calculated for two hours of

Ballast/Driver

Power Use operation scenarios and weighted.

1-lamp: 7 watts

2-lamp: 14 watts

5% of fixture power

High Power

7 watts

Low Power

4 watts

10% of fixture power

Manufacturers'

Specifications

28W T8

Grainger Catalog

Source

Manufacturers'

Specifications

Manufacturers'

Specifications

Install LED fixture in new open display cases

Refrigeration system savings due to reduced heat load from direct lighting energy savings

The approach applies the EER of the refrigeration system to the portion of direct lamp energy savings that would have been rejected to the refrigerated space.

Portion of lamp energy rejected to the refrigerated space is based on lamp location within the case.

Savings are calculated for two hours of operation scenarios and weighted. For 1-lamp fixture baseline measures, savings are also calculated for two lamp location scenarios and weighted.

EER 10.9

DOE2.2R Model from GrocerSmart

3.0

10

Cost, O&M Savings, and Measure Life

Cost Based On

• Distributor Pricing, Marked-up 25%

– 4-foot Fixture

» High Power = $119.57

» Low Power = $93.08

– Driver (per fixture) = $28.13

» (assumes 2 fixtures per driver)

– Hardware (per fixture) = $1.63

• Labor @ $25 per fixture

– (not applicable to new cases)

O&M Savings Based On

• LED Reports (no lamp replacement costs)

– PG&E Application Assessment #0722

– SMUD Report: LED Freezer Case Lighting Systems

Measure Life Based On

• ~50,000 hour life @ ~24 hours per day

11

Proposed Deemed Measures

Procost Full Measure Nam e

Open Case Lights - Low Pow er LED from T12

Open Case Lights - Low Pow er LED from T8

Open Case Lights - High Pow er LED from T12

Increm ental

Capital Cost

($/unit)

Increm ental

O&M Costs

($/unit)

Measure

Life

(years)

Annual

Savings

@ Site

(kw h/yr)

$ 36.96 $ (1.09) 6.0

65

$ 36.96 $ (1.09)

$ 43.58 $ (2.18)

6.0

6.0

38

133

Open Case Lights - High Pow er LED from T8

Open Case Lights - Delam p T12

$ 43.58 $ (2.18) 6.0

$ - $ - 6.0

Open Case Lights - Delam p T8 $ - $ - 6.0

Open Case Lights - LED High Pow er - New Case $ 19.22 $ (2.18) 6.0

Open Case Lights - LED Low Pow er - New Case $ 15.98 $ (1.09) 6.0

81

100

74

62

28

Total

Societal

Benefit /

Cost Ratio

(TRC B/C

Ratio)

0.9

0.6

1.5

1.0

9,999

9,999

2.5

1.4

Incremental Capital and O&M Costs and Annual Savings @ Site are per linear foot of fixture.

DECISION?

12

Evaporator Fan Motor Controller (ECM) for Walk-in Coolers and Freezers

Deemed Measure Proposal

Regional Technical Forum

September 28, 2010

Analysis Prepared By:

RTF Subcommittee

Review?

PECI (Lagan Todd)

Yes (Sept 2, 2010)

RTF Staff Review?

Yes (Adam Hadley)

Presentation Prepared By: RTF Staff (Adam Hadley)

Measure Description

• Standard Practice:

– Evaporator fans run continuously

• Except during the defrost cycle in freezers

• Measure

– Install a controller to reduce the speed or turn off of the evaporator fan motors when there’s no call for cooling

• Savings

– Reduced energy use of the slower/off motor

– Reduced load on the refrigeration system

• Requirements

– This measure only applies where

• the evaporator fan motor is an ECM

• the evaporator is on a circuit with a liquid line solenoid

• motors have rated (nameplate) output power capacity of at least 16W

– Controller must reduce motor speed to not more than 600 RPM when there is no call for cooling.

– If the fan motors are cycled on/off, there must be a provision to prevent stratification.

14

Subcommittee Review

• Meeting held September 2, 2010

(meeting notes available at: http://www.nwcouncil.org/rtf/subcommittees/grocery/meetings/meetings.htm

)

Attendees

• PECI: Lagan Todd, Jen Shafter, Dustin Bailey, Ben Cartwright, Paul

Schertz, Ben Wright, Michele Friedrich, Jamie Anthony

• RTF/Other: Diwanshu Shekhar, Charlie Grist, Eric Brateng, Tim Steele,

Adam Hadley, David Baylon

• Meeting Summary:

PECI generated the analysis and presented its proposal to the subcommittee

The group reviewed key input parameters and supporting data sources in detail

Conclusion: PECI’s savings calculation approach is reasonable.

With a few revisions to input assumptions, this measure could be deemed.

15

Subcommittee Meeting Follow-up

PECI’s follow-up was emailed to the Subcommittee on Sept 16 th

• Measures are now disaggregated by motor size and case temperature

– (previously, one weighted savings value was proposed)

• Refrigeration system savings make up:

– 27% of the total savings for Medium Temp

– 47% of the total savings for Low Temp

• Recommend the following assumptions based on a field study of condenser/compressor runtimes of 5 LT and 7 MT walk-ins

– Low Temp

• Evaporator Fan at Full Speed: 68%

• Evaporator Fan at Low Speed: 32%

– Medium Temp

• Evaporator Fan at Full Speed: 58%

• Evaporator Fan at Low Speed: 42%

• Recommend using 2.5 for the exponent in the fan law calculation

– (savings more conservative than when using 2.7)

• Allow on/off type controllers.

– Savings are only slightly lower (~5%) than full speed/low speed type controllers

• 1 minute on / 7 minutes off assumed as the control strategy for on/off type controller

• EER values based on PECI’s extensive audit data, filtered for eligible applications (nearly 8000 systems)

16

Metered(!) Data on ECM Power

(the following was not reviewed by the subcommittee)

Walk-In Fan Motors - Most, if not all (? the reports were unclear) ECMs are NRM model ME-59

Store

Grocery Store C

Grocery Store B

Markus Foods

Pacific PUD

Dairy Cooler

Meat Prep

Beer Cooler

Description

Produce Cooler

Fish Cooler

Yogurt/Juice

Dairy Cooler

Beer Cooler

Produce Cooler

Meat Prep Closed Area

Meat Cooler

Beverage Cooler

Dairy Cooler

Deli Freezer

Back Freezer

Produce Cooler

Beverage Cooler

Number of Evap Fan

Motors

4

9

8

8

8

6

4

2

4

4

4

1

9

3

2

8

2

4

10

ECM

Watts/motor

80

30

60

48

51

15

60

62

41

63

50

21

51

20

17

55

16

43

93

• Source: BPA/EMP2 M&V Studies

– Frank, David. EMP2. "Markus Foods M&V Findings: Anti-Sweat Heater Control and ECM Motors." January 2009

– Frank, David. EMP2. "Grocery Store M&V: Grocery Store B." For BPA. Jan 29, 2010.

– Frank, David. EMP2. "Grocery Store M&V: Grocery Store C." For BPA. January 29, 2010.

– Amundson, Todd. BPA. "Pacific PUD Four Grocery Stores with Vendor Grovery Energy Management System." October

31, 2006.

17

14

12

10

8

6

4

2

0

Metered Data from 4 Stores

Walk-in Evaporator Fan ECMotor Power Consumption n=100 motors; median = 50 W; avg = 49.5 W

ECMotor Input Watts

Note: Most (if not all) motors were model ME-59. All reports did not specify whether some were ME-30 (or ME-25).

18

Proposed Input Power

Assumptions

1/20 to 1/10 hp Motor Class

Input Power = 50 watts

• Based on median from metered data

16 to 23 Watt Motor Class

Input Power = 19.6 watts

• Based on applying the ratio of metered-to-estimated from the large motor class to the estimated input watts for the small motor class.

– Original motor input estimates were based on the output watts (assumed the middle of the range), divided by an assumed motor efficiency of 66%

Revised Estimate for 16-23 watt motor class

Original Estimate for 1/20-1/10 hp class

Metered Data for 1/20-1/10 hp class (median)

Ratio (metered to estimated)

Original Estimate for 16-23 watt motor class

Revised Estimate for 16-23 watt motor class

75.4

50.0

66%

29.5

19.6

watts watts watts watts

19

Summary of Methdology and Sources for Unit Energy Savings Estimate

Measure Classification and Properties

Market Sector

New / Existing

Market Segment

Commercial

Existing

Grocery

Measure Category

RTF Workbook:

Evaporator Fan ECMotor Controller on Walk-ins

Grocery_EvaporatorFanControllerECMWalkIn_FY10v1_0.xls

Number of

Measures, and UES 4 measures with 2 UES components each

Measure Identifiers

Identifier

Motor Size

Possible Values

Either: a. within the range of 1/10 to 1/20 horsepower; or b. within the range of 16 to 23 Watts

Case Temperature Low Temperature

Medium Temperature

Constant Parameters

Parameter

Fan Law Exponent

Fan Speed at full speed

Fan Speed at low speed

Performance Degradation Factor

Possible Values

2.5

1550 rpm

550 rpm

98%

Further Explanation and Sources

Assumed. Theoretical value is 3. Reduced to 2.5 to adjust for losses.

1550 RPM is the most common rotational speed of WI evaporator fan motors

An average of two industry-recommended low speed settings

(500 and 600)

PECI assumption from GrocerSmart software

20

Summary of Methdology and Sources for Unit Energy Savings Estimate (Continued)

Unit Energy Savings (UES) Estimation Method, Parameters and Sources

Measure Type UES

Component

Analysis approach Primary

Parameter /

Adjustment

Factor

Baseline

Description

Efficient Case

Description

Baseline Source Efficient Case

Source

Installation of a motor controller on the evaporator fan motor in a walk-in cooler or freezer to either turn off or reduce the speed of the evaporator fan when there's no call for cooling.

Direct motor energy savings

Baseline energy use is the product of fan runtime at full speed and fan input power at full speed.

Efficient Case energy use is the product of fan runtime at full speed and fan input power at full speed, plus the product of fan runtime at low speed and fan input power at low speed.

Affinity laws are used as the basis for calculation of fan input power at low speed.

Fan Duty

Cycle

Full-speed fan motor input power

Medium Temp

Full Speed: 100%

Off: 0%

Low Temp

Full Speed: 96%

Off: 4%

Medium Temp

Full Speed: 58%

Low Speed: 42%

Low Temp

Full Speed: 68%

Low Speed: 32%

50.0 Watts

(for the 1/10 to 1/20 hp motor size category)

19.6 Watts

(for the 16 to 23 watt motor size category)

Assumed based on "always on" operation, except

Low Temperature turns off for periods of coil defrost (assumed at 1 hour per day).

Compressor runtimes used as a proxy.

Data from: "Analysis of Cooler Control energy Conservation

Measures, Final

Report" Submitted to

NSTAR Electric by

Select Energy (Impact

Evaluation of NRM measures dated

March 3, 2004)

Input power for the larger motor class is based on data from 100 metered walk-in evaporator fan ECMotors in 4 grocery stores (BPA/EMP2).

For the smaller motor class, a ratio of metered to expected input power for the lager motor class is applied to the expected intput power for the smaller motor class. Expected input power is the middle of the range of output power (19.5

W), divided by the expected motor efficiency (66%).

Refrigeration system savings due to reduced heat load from direct motor energy savings

The approach applies the EER of the refrigeration system and with a performance degradation factor to the direct motor energy savings.

EER

9.60 (Medium Temperature)

4.17 (Low Temperature)

Calculated weighted average from PECI audit data for estimated applicable equipment.

Data and weighting occur in a separate workbook: "Eng-Calc-weighted EER- WI

Evap Fan Control- ECM 100921.xlsx"

21

Cost & Measure Life

Cost: $141 / motor

Installed Cost: $565

Controller (Frigitek, Retail): $325 / controller

Labor: 3 hrs/controller @ $80/hr = $240 / controller

4 motors/controller

On average, > 4 motors per controller

Measure Life: 15 years

Note: Costs are shown in year 2010 dollars.

22

Proposed Deemed Measures

Procost Full Measure Nam e

Evaporator Fan ECMotor Controller - Walk-In - Medium Tem p - 1/10-1/20 HP

Evaporator Fan ECMotor Controller - Walk-In - Low Tem p - 1/10-1/20 HP

Evaporator Fan ECMotor Controller - Walk-In - Medium Tem p - 16-23 W

Evaporator Fan ECMotor Controller - Walk-In - Low Tem p - 16-23 W

Increm ental

Capital Cost

($/unit)

$ 129

Annual

Savings

@ Site

(kw h/yr)

264

Total Societal

Benefit / Cost

Ratio (TRC B/C

Ratio)

2.1

$ 129

$ 129

$ 129

207

104

81

1.6

0.8

0.6

Incremental Capital Cost and Annual Savings @ Site are per motor.

Note: Costs are shown in year 2006 dollars.

23

Issue:

Cost-effectiveness depends on # motors per controller

Motors per

Controller

5

6

7

1

2

3

4

TRC B/C Ratio

1/10 to 1/20 hp motor 16 to 23 watt motor

Med Temp Low Temp Med Temp Low Temp

0.5

0.4

0.2

0.2

1.0

1.5

2.1

2.6

3.1

3.6

0.8

1.2

1.6

2.0

2.4

2.8

0.4

0.6

0.8

1.0

1.2

1.4

0.3

0.5

0.6

0.8

0.9

1.1

Alternative RTF Staff Proposal

• Further disaggregation of the measure:

– Large Motor Class (1/10 to 1/20 HP)

• 3 or more motors controlled per controller

– Average of 5.8 motors per controller

• 1 or 2 motor per controller

– Average of 1.8 motors per controller

– Small Motor Class (16 to 23 watts)

• 6 or more motors controlled per controller

– Average of 8.2 motors per controller

• 1 to 5 motors controlled per controller

– Average of 2.8 motors per controller

Note: This issue and proposal was not reviewed at the subcommittee meeting.

24

Histogram: Number of Fans per Walk-in

(from 7,864 Walk-ins in PNW)

2500

2000

1500

1000

500

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 >20

Number of Fans

Total MT LT

Data Source: PECI 25

Alternative (RTF Staff) Proposed Measures

Total

Societal

Benefit /

Cost Ratio

(TRC B/C

Ratio) Procost Full Measure Name

Incremental

Capital Cost

($/unit)

Annual

Savings

@ Site

(kwh/yr)

Evaporator Fan ECMotor Controller - Walk-In - Medium Temp - 1/10-1/20 HP - 3 or more motors/controller $ 88 264

Evaporator Fan ECMotor Controller - Walk-In - Low Temp - 1/10-1/20 HP - 3 or more motors/controller $ 88 207

Evaporator Fan ECMotor Controller - Walk-In - Medium Temp - 16-23 W - 6 or more motors/controller $ 63 104

Evaporator Fan ECMotor Controller - Walk-In - Low Temp - 16-23 W - 6 or more motors/controller $ 63 81

Evaporator Fan ECMotor Controller - Walk-In - Medium Temp - 1/10-1/20 HP - 1 or 2 motors per controller $ 283 264

Evaporator Fan ECMotor Controller - Walk-In - Low Temp - 1/10-1/20 HP - 1 or 2 motors per controller $ 283 207

Evaporator Fan ECMotor Controller - Walk-In - Medium Temp - 16-23 W - 1 to 5 motors per controller

Evaporator Fan ECMotor Controller - Walk-In - Low Temp - 16-23 W - 1 to 5 motors per controller

$ 182 104

$ 182 81

3.0

2.3

1.7

1.3

0.9

0.7

0.6

0.4

Incremental Capital Cost and Annual Savings @ Site are per motor.

Provisionally Deemed:

-18 month sunset period

-Data Collection Should Include:

-Metered ECMotor power input

-Metered ECMotor Runtimes

-Full Speed

-Off/Low Speed

DECISION?

26

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