Draft STANDARD SAVINGS ESTIMATION PROTOCOL FOR VAV CONVERSION Submitted to REGIONAL TECHNICAL FORUM Submitted by SBW CONSULTING, INC. 2820 Northup Way, Suite 230 Bellevue, WA 98004 January 28, 2011 Standard Savings Estimation Protocol for VAV Conversion TABLE OF CONTENTS 1. PURPOSE............................................................................................................ 1 2. DEFINITION OF KEY TERMS ..................................................................................... 1 3. ELIGIBLE PROJECTS ............................................................................................... 1 4. REQUIRED KNOWLEDGE AND SKILLS OF PRACTITIONER ................................................... 2 5. REQUIRED COMMISSIONING .................................................................................... 2 6. DATA COLLECTION REQUIREMENTS ........................................................................... 3 6.1. Fan and Fan Motor Specifications ..................................................................................... 3 6.2. Fan Operations ................................................................................................................... 3 6.3. Post-Period Electrical Measurements................................................................................ 3 6.4. Facility Control System Post-Period Trend Logs ................................................................ 4 6.5. Alternate Baseline and Post measurements ..................................................................... 5 6.6. Typical Meterological Year (TMY) Weather Data .............................................................. 5 6.7. Inputs for Cost-Effectiveness Analysis ............................................................................... 5 7. PROVISIONAL DATA REQUIREMENTS ......................................................................... 6 8. SAVINGS ESTIMATION STEPS ................................................................................... 6 8.1. Compute Savings for Trend Log Intervals .......................................................................... 6 8.1.1. Fan Savings and Post Airflow for Trend Log Intervals ........................................................ 7 8.1.2. Heating Savings for Trend Log Intervals ............................................................................. 7 8.1.3. Cooling Savings for Trend Log Intervals .............................................................................. 8 8.2. Annualized Savings: Determined by OAT and Facility Schedule........................................ 9 8.3. Alternative Method............................................................................................................ 9 8.4. Total Energy Savings ........................................................................................................ 10 8.5. Life Cycle Costs and Benefits ........................................................................................... 10 9. SAMPLING PROCEDURE ........................................................................................ 10 10. RELATIONSHIP TO OTHER PROTOCOLS AND GUIDELINES ............................................. 11 11. TYPICAL COST OF APPLYING THIS PROTOCOL ........................................................... 11 12. USER’S GUIDE TO SAVINGS CALCULATOR ................................................................ 12 SBW Consulting, Inc. i Standard Savings Estimation Protocol for VAV Conversion 1. PURPOSE This protocol establishes a method by which annual electrical energy savings (kWh) can be estimated for a Constant Volume (CV) HVAC system that has been upgraded to a Variable Air Volume (VAV) system by the addition of a Variable Frequency Drive (VFD) and new terminal units. VAV systems use less energy than CV systems as they reduce airflow and thus require less energy to condition the air that is delivered to the space. Fan energy is also reduced from the reduced airflow and further reduced by the efficient nature of the VFD. This protocol specifies minimum acceptable data collection requirements and the method by which these data are to be used in computing savings for CV to VAV conversion projects. For some data elements, alternative sources of data, considered to be of superior quality, are also defined and are allowed. Savings are computed using the Excel workbook (to be developed) that accompanies this document to ensure standardized application of the savings estimation methods. 2. DEFINITION OF KEY TERMS Project. Installation of new variable volume terminal units as needed to meet conditioning load for the portion of a building served by a single air handler and installation of VFDs on the supply and return fans for that air handler. The volume of air to conditioned spaces varies with respect space cooling and heating load. The VFD speed on the supply fan is determined by the pressure in the distribution air duct. If present, the VFD speed on the return fan is determined by either the supply fan speed or building pressure differential (either between interior spaces or relative to ambient). Baseline. This modifier; as in baseline control strategy has one of two meanings. For HVAC systems upgraded in existing facilities, it refers to the period prior to the upgrade. For HVAC systems in new construction, there is no such period. For them, the term baseline refers to the design specification for the HVAV system without the efficiency upgrade. Post. This modifier; as in post current trend log, refers to the period after the fan unit VFD upgrade is installed and fully commissioned. Commissioning. This is the process of testing and adjustment required to ensure that the VAV system is operating according to its design intent. 3. ELIGIBLE PROJECTS The following criteria define eligible projects. Heating for the system must be electric resistance. Cooling may be either DX (direct expansion) or chilled water coil. However, if the alternate method (see section 6.5) is used, only DX is eligible. Fan motors must be single speed motors. SBW Consulting, Inc. 1 Standard Savings Estimation Protocol for VAV Conversion If new construction or major renovation, the HVAC systems must not be subject to local energy code requirements for variable air volume systems. The air distribution must be a single duct system. Multi-zone and dual duct systems are excluded, unless using the alternate method (see section 6.5). Systems with reheat in the terminal units are eligible (baseline terminal reheat units converted to VAV terminal units with reheat). Systems with other zone heating units such as perimeter baseboards are excluded. Systems that are designed with simultaneous heating and cooling are excluded. Terminal reheat must be disabled, when the cooling coil is active Damper control of mixed air temperature (mixing of outside and return air) must be the same for both the baseline and post conditions. The exception for this is if the alternative baseline and post measurements and calculations are made (see section 6.5). No other significant building changes that affect the heating and cooling loads such as improved thermal envelope, lighting changes, schedule or occupancy changes occur between the baseline and post periods VFD %speed must be available as a point on the building control system that can be captured in a trend log. The cost of implementing this protocol must not make the VFD project economically unattractive. 4. REQUIRED KNOWLEDGE AND SKILLS OF PRACTITIONER The practitioner who has lead responsibility for applying this protocol must have a full understanding of the following: Appropriate safety procedures for work involving HVAC systems and the measurement equipment required by this protocol This protocol and the accompanying savings calculator. The practitioner must also be able to successfully perform the following tasks: Identify, by inspection, the HVAC system configuration, equipment and control settings to verify eligibility and complete the commissioning tasks. Identify, by interview and inspection the facility operations schedule. Install and operate true power, current and temperature loggers and obtain necessary trend logs from facility control systems. 5. REQUIRED COMMISSIONING This protocol may only be used for HVAC systems that pass the following commissioning tests: 2 SBW Consulting, Inc. Standard Savings Estimation Protocol for VAV Conversion Fan (supply and if present, return) unit is responding to the control sensor signal and is monitored from the facility control system at the beginning of the trend log period (see section 6.4). Practitioner confirms that installation commissioning tests demonstrated correct operation of outside, return and exhaust dampers and the VAV terminal units. Practitioner confirms by examining a plot of %speed vs. current that the fan unit(s) was responding to the control signal at least 90% of the trend log period (see 6.4). 6. DATA COLLECTION REQUIREMENTS The following data must be collected and entered into the savings calculator. The minimum acceptable procedure for obtaining the data is specified. In some cases, alternative procedures are allowed which would provide data of higher quality. 6.1. Fan and Fan Motor Specifications Full Load Air Flow. Taken from the equipment schedule on the facility’s mechanical plan. Alternatively, this value may be determined by: (1) inspecting facility control system trend logs of fan flow rate, if the system has a calibrated flow sensor and the log contains values at or near 100% speed or (2) taken from an air balance report. Cooling efficiency. Obtain the performance of the cooling system (DX or chiller). The Integrated Part Load Value (IPLV) can be obtained from the manufacturer’s literature, which should be part of the contractor submittals. Fan Motor HP. Obtained from the motor name plate of the supply fan and return fan, if present. Full load fan kW (computed by the savings calculator) should not exceed 115% of fan motor nameplate HP times 0.746. 6.2. Fan Operations Facility Operations Schedule. Obtained from facility operator. Obtain the fan hours of operation by hour of day, day of week and season. If fan unit has different operation modes determined by the facility’s operations schedule, e.g., setback of airflow during night and weekend hours, determine the periods for each of these modes (hour of day, day of week and season). Weather Station. If OAT is a significant determinant, identify the TMY (Typical Meteorological Year) weather station which is closest to the project site. 6.3. Post-Period Electrical Measurements Trend Log of fan VFD Power. A data logger is installed to measure 15-minute interval true RMS power on the circuit powering the supply and return fan VFDs. The measurement period must SBW Consulting, Inc. 3 Standard Savings Estimation Protocol for VAV Conversion include periods of the system operating in both heating and cooling mode. If the fan unit speed is also determined by facility operating schedule the period must also capture all the different operating modes. Trend log of Terminal Unit Current. Data loggers installed to measure 15-minute interval current for circuits serving the terminal units. This can be panel or switch gear level measurement which combines more than one unit. It can also be for a random sample of units as described in section 9. The measurement period must include at least 3 weeks of terminal unit heating use. Note: some units may have small fan loads during non-heating periods, which should be ignored. Trend log of Central Heating Coil Current. If present, data loggers installed to measure 15-minute interval current of all heating coils located in the air handler or air distribution system other than the terminal units. The measurement period must include at least 3 weeks of heating coil use. 6.4. Facility Control System Post-Period Trend Logs All trend log data must be collected concurrently for all required variables, during the same period as the fan VFD power measurements in section 6.3. Trend Log of VFD % Speed. The facility’s control system is programmed to record VFD % speed for the supply fan and, if present, return fan, at 15-minute intervals. Trend Log of Mixed Air Temperature. The facility’s control system is programmed to record the mixed air temperature (MAT) in the air handler at 15-minute intervals. This is the air temperature after mixing of outside and return air and before any heating or cooling coils. If the control system does not have this control point available for trending, a temperature logger can be placed in the air handler to capture this data. Trend Log of supply Air Temperature. The facility’s control system is programmed to record the supply air temperature (SAT) in the air handler at 15-minute intervals. This is the air temperature immediately downstream of the cooling coil. If the control system does not have this control point available for trending, a temperature logger can be placed in the air handler to capture this data. Space Temperature. The facility control system is programmed to record the air temperature, at 15minute intervals, in the conditioned space for a random sample of locations, as defined in section 9. If the control system does not have this information for trending, then temperature loggers can be placed near thermostats (temperature sensors) in the space to capture this data. Trend Log of VFD Facility OAT. The facility’s control system is programmed to record OAT at 15minute intervals. If OAT is not available from the facility’s control system or appears unreliable, an OAT data recorder should be installed to create this trend log. 4 SBW Consulting, Inc. Standard Savings Estimation Protocol for VAV Conversion 6.5. Alternate Baseline and Post measurements This alternative supersedes the measurements in section 6.3 and 6.4 and can only be used if the system cooling is by DX and the project is retrofit. This method will also capture energy savings associated with other changes to the HVAC system that may have occurred such as repair of economizers and changes in MAT controls. One-Time Baseline Fan Power. Take a one-time true RMS power measurement on the circuit serving the supply fan, and if present, the return fan. Trend Log of Post Fan VFD Power. A data logger is installed to measure 15-minute interval true RMS power on the circuit powering the supply and return fan VFDs. The measurement period must include periods of the system operating in both heating and cooling mode, during the post period. If the fan unit speed is also determined by facility operating schedule the period must also capture all the different operating modes. Trend log of Baseline and Post Terminal Unit Current. Data loggers installed to measure 15-minute interval current for circuits serving the terminal units. This can be panel or switch gear level measurement which combines more than one unit. It can also be for a random sample of units as described in section 9. The measurement period must include at least 3 weeks of terminal unit heating use during the baseline and post periods. Note: some units, in the post period, may have small fan loads during non-heating periods, which should be ignored. Trend log of Baseline and Post Central Heating Coil Current. If present, data loggers installed to measure 15-minute interval current of all heating coils located in the air handler or air distribution system other than the terminal units. The measurement period must include at least 3 weeks of heating coil use during the baseline and post periods. Trending of baseline and post DX cooling. Install true RMS power loggers on the cooling components (compressors and condensers) of the cooling equipment solely dedicated to the converted HVAC system. Measurements that combine components at the panel or switchgear are allowed. 6.6. Typical Meterological Year (TMY) Weather Data TMY OAT. Typical Hourly OAT data for Pacific Northwest weather stations are contained in the savings calculator to be used in estimating annual saving. Data from the station selected in 6.2 will be used. 6.7. Inputs for Cost-Effectiveness Analysis The following data need to be gathered to support the cost/benefit analysis feature of the calculator. Project completion date. SBW Consulting, Inc. 5 Standard Savings Estimation Protocol for VAV Conversion Measure cost. The initial cost of installing the new equipment, including all materials and labor costs. This is the full cost of the project. This value must be supported by invoices or other documentation. Sector. Possible values are Agricultural, Industrial, and Commercial. The following values are used in the cost-effectiveness calculation, but are pre-set in the calculator. Electric shape. The calculator assigns an appropriate electric shape based operation data describe in section 6.2 and the profile of savings computed from the trend log data. Periodic costs or savings. Any non-annual periodic costs associated with the measure, and the associated time period. These are incremental costs of the efficient option over the costs of the baseline. For a fan VFD, the calculator restricts this value to be zero. O&M costs or savings. Annual O&M costs or savings associated with the measure. These are costs or savings which occur with the efficient option that would not occur with the baseline option, i.e. the costs associated with VFD maintenance. Interview the building operator to determine the likely cost of filter maintenance for the VAV terminal units. Non-energy benefits. Annual non-energy related costs or savings associated with the measure. The calculator restricts this value to be zero. Measure life. Number of years the measure is expected to be in effect. For this project, the calculator restricts this value to be 10 years. 7. PROVISIONAL DATA REQUIREMENTS During the period that the RTF classifies this protocol as Provisional, the following data requirements will be in force: Alternate Measurements. For retrofit projects, with DX cooling, the alternate measurements (section 6.5) must be taken in addition to those required by sections 6.3 and 6.4 8. SAVINGS ESTIMATION STEPS Savings are estimated using the savings calculator that accompanies this protocol (to be developed). Savings are estimated as follows. 8.1. Compute Savings for Trend Log Intervals 6 Data Synchronization. Start times for all trend log intervals are synchronized by moving each to the closest standard interval starts times of 0, 15, 30 and 45 minutes after the start of each hour. SBW Consulting, Inc. Standard Savings Estimation Protocol for VAV Conversion Total Heating Power. For each interval, all terminal unit power measurements are summed. If terminal units were sampled, this is a sample weighted sum. All central heating coil measurements are added to the system. Total Cooling Power. For each interval, cooling component power measurements are summed. Average Space Temperature. For each interval, the sampled space temperature measurements are averaged. 8.1.1. Fan Savings and Post Airflow for Trend Log Intervals Fraction of Full Flow. Equals the fraction of full speed from the %speed trend log. Post Airflow (Post_cfm). Equals the fraction of full speed times the full speed rated airflow. Fan Motor Full Load kW. Average the kW values corresponding to %speed values greater than 99%. If there are any such values, use this average to define fan full load kW. If not, an exponential curve fit to the power vs. speed relationship is used to estimate this value at 100% speed. Baseline fan kW. Calculate baseline kW as the product of the fan motor full load kW and the VFD efficiency (default = 97%). Fan Savings for Trend Log Period. Calculate the savings as the difference between the constant baseline fan kW and measured post kW for each trend log interval. 8.1.2. Heating Savings for Trend Log Intervals Post Heat (Post_heat). Convert the post measured heat to Btu/hr. by multiplying the trended heat kW value by 3,413. Post Delivered Air Temperature (Post_DAT). Calculate the post delivered air temperature by the equation: Post_DAT = MAT + (Post_heat / 1.1 X Post_cfm) Where, MAT is the measured mixed air temperature trended value, and 1.1 converts cfm to BTU / degree F. Heating Load on the Conditioned Space (Space_H_load). Calculate the amount of heating load on the conditioned space by the equation: Space_H_load = 1.1 X Post_cfm X (Post_DAT – Space_temp) Where, Space_temp is the averaged space temperature trended value, and 1.1 converts cfm to BTU / degree F. Baseline Delivered Air Temperature (Base_DAT). Calculate the delivered air temperature at the baseline airflow rate required to meet the space heat load by the equation: SBW Consulting, Inc. 7 Standard Savings Estimation Protocol for VAV Conversion Base_DAT = MAT + (Space_H_load / 1.1 X Base_cfm) Where, Base_cfm is the full speed rated airflow value, and 1.1 converts cfm to BTU / degree F. Baseline Heat (Base_heat). Calculate the amount of heat that would have been required at the baseline constant airflow rate by the equation: Base_heat = (1.1 X Base_cfm X (Base_DAT – Space_temp)) / 3,413 Where, 3,413 is the conversion into units of kW, and 1.1 converts cfm to BTU / degree F. Heat Savings for Trend Log Period. Calculate the savings by the equation Heat Savings = Base_Heat – (Post_Heat / 3,413) Where, 3,413 is the conversion into units of kW. 8.1.3. Cooling Savings for Trend Log Intervals Post Cool (Post_Cool). Calculate the post cooling to the supply air temperature by the equation: Post_Cool = 1.1 X Post_cfm X (MAT – Post_SAT) Where, Post_SAT is the measured air temperature downstream of the cooling coil,MAT is the measured mixed air temperature trended value, and 1.1 converts cfm to BTU / degree F. Post Cool kW. Calculate the post cooling by multiplying Post_Cool by the cooling efficiency (calculator derives COP based on rated IPLV and units of that rating) and dividing by 3,413. Cooling Load on the Conditioned Space (Space_C_load). Calculate the amount of cooling load on the conditioned space by the equation: Space_C_load = 1.1 X Post_cfm X (Space_temp - Post_SAT) Where, Space_temp is the measured room temperature trended value, and1.1 converts cfm to BTU / degree F. Baseline Cooled Supply Air Temperature (Base_SAT). Calculate the air temperature downstream of the cooling coil at the baseline airflow rate required to meet the space cooling load by the equation: Base_SAT = MAT - (Space_C_load / 1.1 X Base_cfm) Where, Base_cfm is the full speed rated airflow value, and1.1 converts cfm to BTU / degree F. Baseline Cool kW (Base_Cool). Calculate the amount of cooling that would have been required at the baseline constant airflow rate by the equation: Base_cool = (1.1 X Base_cfm X (Spac_temp - Base_SAT ) X COP) / 3,413 Where, 3,413 is the conversion into units of kW, COP is the cooling efficiency of the cooling system, and 1.1 converts cfm to BTU / degree F. 8 Cooling Savings for Trend Log Period. Calculate the savings by the equation SBW Consulting, Inc. Standard Savings Estimation Protocol for VAV Conversion Cooling Savings = Base_ Cooling – (Post_ Cooling / 3,413) Where, 3,413 is the conversion into units of kW. 8.2. Annualized Savings: Determined by OAT and Facility Schedule Fan, heating and cooling savings are annualized as follows: Average Savings by Trend Log Bin. For each operating mode, average kW savings by two degree temperature bins for all trend log intervals during operating hours, as defined by facility operations schedules (Section 6.2). Operating Hours by TMY Bin. For each operating mode, divide the 8,760 TMY OAT data into two degree bins and compute frequency of annual operating hours for each temperature bin, as defined by facility operations schedules (Section 6.2). Average Savings by TMY Bin. For each operating mode, TMY bin average savings equal trend log average bin savings for each matching bin. Extrapolate average savings for TMY bins that do not have trend log data. For fan savings, higher temperature bins are extrapolated by a linear equation fit to the trend log bins above 60 degrees and lower temperature bins by a linear equation fit to the bins below 55 degrees. For heating savings, values are extrapolated by a best fit equation to the trend log bins. Negative values will likely occur at temperatures greater than about 60F and should be set to zero. For cooling savings, values are extrapolated by a best fit equation to the trend log bins. Negative values will likely occur at temperatures less than about 60F and should be set to zero. Saving by Bin. In each operating mode, for each TMY bin, multiply the average bin savings by the number of operating hours in each bin, to get kWh savings in each bin. Annual Savings. Sum the kWh values across the TMY bins for both operating modes. 8.3. Alternative Method This method assumes that data is collected in accordance with sections 6.1, 6.2, 6.5 and 6.6. Data Synchronization. Start times for all trend log intervals are synchronized by moving each to the closest standard interval starts times of 0, 15, 30 and 45 minutes after the start of each hour. Average Heating Power by Trend Log Bin. For each interval, all terminal unit power measurements are summed. If terminal units were sampled, this is a sample weighted sum. All central heating coil measurements are added to the system. Base_Heat is the values during baseline period and Post_Heat is the values during the post period. For each operating mode, average kW by two degree temperature bins for all trend log intervals during operating hours, as defined by facility operations schedules (Section 6.2). SBW Consulting, Inc. 9 Standard Savings Estimation Protocol for VAV Conversion Average Cooling Power by Trend Log Bin. For each interval, cooling component power measurements are summed. Base_Cool is the values during baseline period and Post_Cool is the values during the post period. For each operating mode, average kW by two degree temperature bins for all trend log intervals during operating hours, as defined by facility operations schedules (Section 6.2). Average Fan Power by Trend Log Bin. Base_Fan is from one-time measurement, assumed to be constant for all baseline intervals per the operating schedule. Post_Fan is from the trend logger. For each operating mode, average kW by two degree temperature bins for all trend log intervals during operating hours, as defined by facility operations schedules (Section 6.2). Average Power by TMY Bin. For each operating mode, TMY bin average power (heat, cool, and fan) equal trend log average bin power for each matching bin. Extrapolate average power for TMY bins that do not have trend log data. For fan power, higher temperature bins are extrapolated by a linear equation fit to the trend log bins above 60 degrees and lower temperature bins by a linear equation fit to the bins below 55 degrees. For heat power, values are extrapolated by a best fit equation to the trend log bins. Negative values will likely occur at temperatures greater than about 60F and should be set to zero. For cool power, values are extrapolated by a best fit equation to the trend log bins. Negative values will likely occur at temperatures less than about 60F and should be set to zero. Annual Fan, Heat and Cool Savings. For fan, heat and cool sum the difference between baseline and post power values times the number of hours in each TMY bin for each operating mode. 8.4. Total Energy Savings For either method, total energy savings are then obtained as the sum of fan, heat and cooling savings. 8.5. Life Cycle Costs and Benefits The calculator contains a model called ProCost which computes life cycle costs and benefits. Inputs to the model include the estimates of first-year savings described in section 8 and the cost-effectiveness input data described in section 6. ProCost computes life cycle costs and benefits from the economic perspectives of the end user, utility, and region. The calculator can be used to review these results. 9. SAMPLING PROCEDURE Terminal units may be sampled if it reduces the cost of measuring current for all units. A list of all units and their rated kW heating capacity (from the mechanical equipment schedule) must be prepared and entered into the calculator. The calculator will select a sample of units form measurement that will provide 80/20 precision in the estimation of total unit kW. The calculator will also provide a list of four random selected terminal units for space temperature measurements. These are accomplished as specified in section 6.4. This sample is always required. If 10 SBW Consulting, Inc. Standard Savings Estimation Protocol for VAV Conversion terminal units are not sampled, a list of the terminal units is entered into the calculator (without heating capacities) so that the random sample can be drawn. 10. RELATIONSHIP TO OTHER PROTOCOLS AND GUIDELINES The relationship between this protocol and other relevant protocols and guidelines is as follows: International Performance Measurement and Verification Protocol – 2007 (IPMVP), Efficiency Valuation Organization. This protocol is consistent with Option A - Retrofit Isolation: Key Parameter Measurement described in the IPMVP, as a number of key parameters are measured (fan motor current, VFD %speed and OAT). Sampling Reference Guide, BPA. Sampling terminal units is allowed under this protocol and is consistent with the BPA guide. Regression Reference Guide, BPA. This protocol uses regression techniques to to extrapolate savings to temperatures beyond those observed in the trend logging period. The application of these regression techniques is consistent with the BPA guide. 11. TYPICAL COST OF APPLYING THIS PROTOCOL Shown below is an estimate of typical cost of applying this protocol. Expense for the alternate pre and post measurements, allowed by this protocol, are not included in this estimate of typical cost. Item Quantity $ / Hour Rental Total Cost Equipment Power Meter 1 100 100 Power Loggers 3 200 600 Current Loggers 10 50 500 Temperature Loggers 4 50 200 Labor Practitioner Travel 3 110 330 Scheduling 1 110 110 Facility Operator Interview 2 110 220 Project Inspection 2 110 220 Electrical Measurements 1 110 110 Install/Remove Logger 8 110 880 Savings Estimate 4 110 440 Travel 2 90 180 Electrical Measurements 4 90 360 Electrician SBW Consulting, Inc. 11 Standard Savings Estimation Protocol for VAV Conversion Item Quantity $ / Hour Rental Total Cost Controls Specialist Setup and Export Trend Logs Total 3 150 450 $4,700 12. USER’S GUIDE TO SAVINGS CALCULATOR [To be developed once this protocol is finalized and savings calculator is developed. This Guide and the Calculator are outside the scope of SBW’s current contract.] 12 SBW Consulting, Inc.