Innovative Technology Drives Real Results · 2018-04-03 · 5.2 Gallons per Hour! Red Lobster –...

RFMA 2016 Annual Conference March 13‐15, 2016

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Innovative Technology Drives RealResults

Curt Sawan – Red LobsterGreg DuChane – TraneSteve Brown - LC Systems

• 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

Presenter Introductions

• 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

What are We going to Learn Today?Curt Sawan


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• History of Red Lobster Restaurant – Clarksville, INBuilding Design (Dining ‐ 40 Tons Total)

1. Three Dining Room Rooftop Units (15, 15 & 10 Ton)2. Single Thermostat per Rooftop Unit3. Sequential Compressor Staging

Inherent Issues1. Inadequate Compressor Run Times ‐ Oversized2. Coverage Area Too Large for Single Thermostat3. Outdoor Air Introduction during Normal Operation

Red Lobster – Clarksville, INBackground & HVAC Issues

Standard Unit Short Cycling

• Problems EncounteredGuest ComfortHigh HumidityMoldEmployee discomfortBuilding Air Balance (Negative Pressure)

Red Lobster – Clarksville, INBackground & HVAC Issues

Red Lobster – Moisture IssuesHigh Indoor Relative Humidity


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Red Lobster – Moisture IssuesHigh Indoor Relative Humidity

Red Lobster – Clarksville, INHVAC Design Layout

• Past ExperiencesOther buildings with same designCurrent equipment‐ asset cost and designAgeSizingAbility to perform as neededHumidity Control Energy efficiencyImplication for future retrofitsDuctworkRemodels

Raised Deck

Lobby

15 Ton Unit

15 TonUnit

10 TonUnit

15 TonUnit

10 TonUnit

Main Dining

Kitchen

Red Lobster – Clarksville, INTotal Outside Air

Building Pressure: +619 CFM


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• 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!

Red Lobster – Clarksville, INMoisture in Outdoor Air

F DB Dry Bulb Temperature (F)F WB Wet Bulb Temperature (F)RH Relative Humidity (%)

• 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/hrgal/hr = 43.1 lbs/hr / 8.33 lb/gal

5.2 Gallons per Hour!

Red Lobster – Clarksville, INFacts of Moisture in Outdoor Air

• 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?

Red Lobster – Clarksville, INOutdoor Air Management


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• Hood operations & Performance• Restaurant Operations• RTU Dehumidification Options available

• Past & Present

Retrofit current equipment ‐ APR DeviceAdd Dehumidifier(s)Hot Gas ReheatOther Options?

Considerations for resolution

• Must be another option?• Future energy consumption & Green Buildings• What new technology is out there to reduce

energy but still get results?

What about energy efficiency?

• 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

New Technology IntroductionGreg DuChane


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Red Lobster – HVAC Test Layout

15 TonHighV3

(New)

15 TonStandard(Existing)

10 TonHighHGRH(New)

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 ResultsPart Load Days & Temperature Variance

Night ‐ Unoccupied

Night ‐ Cleaning


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Red Lobster – System StatusDining Area Occupied Dashboard

Red Lobster – Guest ComfortOutdoor Air Temp: 60 – 85 F

OCCUPIED OCCUPIEDOCCUPIED

Variable Speed – T: 72 F Avg. (74 – 68 F Range)Hot Gas Reheat – T: 72 F Avg. (74 – 70 F Range)Std. Efficiency – T: 72 F Avg. (74 – 70 F Range)

Variable Speed – RH: 40% Avg. (55 – 30% Range)Hot Gas Reheat – RH: 35% Avg. (50 – 30 % Range)Std. Efficiency – RH: 45% Avg. (50 – 30% Range)

72 F

35%

• 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

Red Lobster – Guest ComfortObservations


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• 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

Red Lobster – Guest ComfortIssues & Head Winds

Variable Speed TechnologyCompressor, Indoor Fan & Condenser Fan

Benefits of Variable Speed


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Red Lobster – System StatusDining Area Occupied Dashboard

Variable Speed Vs. HGRH

Red Lobster – Clarksville, INHeat 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, INDining Area Load & Energy Calculations

October Actual EMS


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Red Lobster – Clarksville, IN3 RTU – 12.5 Ton – Dining Roof Sweep

Alt. 1: High EfficiencyAtl. 2: High Eff. – Hot Gas ReheatAlt. 3: High Eff. – Variable Speed

Problem StatementRestaurant was ExperiencingHigh Humidity & DifficultyControlling Building Moisture

Problem SolutionRooftop HVAC Units with HotGas Reheat or Variable Speed

ResultsVariable Speed Rooftop UnitsProvide 2.1 Year Payback Saving Energy & ProvidingComfort & Humidity Control

2.1 YearsVar. Speed

• 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, INLessons Learned

Red Lobster – Clarksville, INLive Data


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Tricks of the TradeYes…We are Geeks!

Airflow MeasurementSmart Phone Interface

Temperature & RHData Logging

Pocket Temperature & RH Sensor

Questions?

Curt Sawan – Red LobsterFacility Manager

Greg DuChane – TraneRetail‐Restaurant National Accounts

• Steve Brown – LCSystems• President, LCSystems, Inc.• ASHRAE TC 5.10 Past Chair

Presenter IntroductionsAirflow Testing Method of Test Update


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T.A.B. Test & Balance Ports

EASE OF BALANCING.

FIELD SYSTEM FOR BALANCING AIR FLOW RATES

KVE-102001.02

qv [cfm]

p s t

[''WC]

10001000 2000 3000

0.100.10

0.20

0.30

0.50

TAB Ports - CKV Air BalanceRELIABLE - ACCURATE - EASY

ASHRAE ResearchMOT Evaluate Field Performance of CKV Systems

Cyclone Filter Results

0

500

1000

1500

2000

2500

3000

3500

4000

0 1000 2000 3000 4000Qactual (SCFM)

Qm

easu

re (S

CFM

)

4" RVA Cold Discrete

4" RVA Cold Traverse

2.75" RVA Cold Discrete

2.75" RVA Cold Traverse

Hot Film Cold Discrete

Hot Film Cold Traverse

Velocity Grid Cold

Flow Hood (2'x4') Cold

Flow Hood (2'x2') Cold

4" RVA Hot Discrete

4" RVA Hot Traverse

2.75" RVA Hot Discrete

2.75" RVA Hot Traverse

Hot Film Hot Discrete

Hot Film Hot Traverse

Velocity Grid Hot

Flow Hood (2'x4') Hot

Flow Hood (2'x2') Hot

K-factor of 1

Most Hand‐Held Devices Report Exhaust Readings are LOW!

Perimeter Results

0

500

1000

1500

2000

2500

3000

3500

0 500 1000 1500 2000 2500Qactual

Qm

easu

red

4'' RVA Cold Discrete

4" RVA Cold Traverse

2.75" RVA Cold Discrete

2.75" RVA Cold Traverse

Hot Film Cold Discrete

Hot Film Cold Traverse

Velocity Grid Cold

4" RVA Hot Discrete

4" RVA Hot Traverse

2.75" RVA Hot Discrete

2.75" RVA Hot Traverse

Velocity Grid Hot

Hot Film Hot Discrete

Hot Film Hot Traverse

K Factor of 1

2'x2' FlowHood Cold

2'x2' FlowHood Hot

ASHRAE ResearchMOT Evaluate Field Performance of CKV Systems

Most Hand‐Held Devices Report Supply Readings that are HIGH!


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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

Exhaust Read 10% Under Design & MUA Read 10% Over Design Field Adjusted =

Design Hand Held Reading Field Adjusted0

500

1000

1500

2000

2500

3000

3500

4000

4500

4000 3600

4400

3200 3520 2880

8001040

1520

Exhaust

MUA

Building

Building Supply 90% over design!

Conclusions

Hood and Fan Pressure TAB Ports

• Require Manufacturer’s Certification

• Customer tool • Maintenance Check• Performance Update

• High Degree of Air Balancing Accuracy

• Easy to Use


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Questions?

Steve Brown – LC SystemsPresident

Innovative Technology Drives Real Results · 2018-04-03 · 5.2 Gallons per Hour! Red Lobster –...

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