PowerPoint Presentation · 2016-05-18 · ARENAS AND STADIUMS • Way overprovisioned –Designed...

05/14/2012

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COOLING CONTROL IN

MANUFACTURING

Dan Mascola

AGENDA

• Promote

• Background

• Understanding Your Facility

• Cooling Control Solutions

– Case Studies

• How To Start on Monday

COOLING CONTROL IN MANUFACTURING | 3

05/14/2012

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PROMOTE

PROMOTE

Thanks electric company!


PROMOTE


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PROMOTE

• Monthly newsletter or email

– Daily facility energy use

– Greenhouse gas emissions...# of cars

– Active energy projects

– Tips tenants can do to reduce energy use

• Posters

• Quarterly events


BACKGROUND

PERSONAL BACKGROUND


• Product Marketing Manager at Vigilent®

• Energy analysis

– Lighting, chillers, boilers, pumps, economizers, ventilation, process

• Building audits and walkthroughs

– Commercial, campus, labs, data centers, manufacturing, industrial

• Program management

– LEED, utility incentives, M&V, RCx, product development

www.dchuddle.com

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ABOUT VIGILENT


• Provides intelligent energy management systems for data centers, telco, central offices and buildings

– Intelligent control – dynamic, predictive, adaptive

– Rapid deployment with minimal incursion

– Instant savings on energy costs

– Uniquely informed by Big Data, directed by Big Analytics

UNDERSTANDING YOUR FACILITY

TYPES OF MANUFACTURING FACILITIES

COOLING CONTROL IN MANUFACTURING |

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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums

• Hospital and Labs

• Processing Plant

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TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

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TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

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TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

TYPES OF LOADS


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

OFFICE BUILDING


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• Be comfortable

• Individual Control

• Occupied/Unoccupied

Resulting HVAC System

• Complex

• Serve diff. zones

• Dynamic control

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WAREHOUSE


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• Be boxes

• Large area to store

and move things


• Non existent?

• Heating in cold climates

• Minimize infiltration

COLD STORAGE


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• Temperature limits

• Requires 24/7

conditioning

• Stored and moved Resulting HVAC System

• Special cooling equipment

• 24/7 operation

• Not dynamic

DATA CENTERS


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• Temperature limits

• Requires 24/7 conditioning

• Mission critical


• Dynamic cooling control

• Super redundant

• 24/7 operation

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PARKING GARAGES


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• Potentially harmful emissions

• Dynamic


• Ventilation heavy

• Dynamic control

• Conditioning not required

ARENAS AND STADIUMS


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• High density of people

• Large Open Space

• Periodic


• Cooling only

• Large ventilation capacity

• Periodic use requires dynamic control

HOSPITALS AND LABS


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• Health requirements

• 24/7 operation

• Mission critical


• Ventilation heavy

• Airflow sensitive

• 24/7 operation

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PROCESSING PLANTS


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People

Boxes

Frozen Food

IT Equipment

Cars

People

Sick People

Almost Anything

• Production lines

• Manufacturing

• Waste Water Treatment


• Facility specific

• Elec. Motors dominate energy use

TYPES OF FACILITIES


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• Office Building

• Warehouse

• Cold Storage

• Data Center

• Parking Garage

• Arenas/Stadiums



Require Cooling

Control Solution

COOLING CONTROL SOLUTIONS

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Data Centers


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DATA CENTERS

• Energy is single largest operating expense

– Overcooled, but IT loads increasing

• 42% of data centers will run out of power,

cooling, or space in the next two years

• Technical Issues

– Existing controls non existent, all on all the time

– No visibility into inlet temperatures

– Manual control is time consuming, error prone


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DATA CENTERS


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DATA CENTERS

• Monitor inlet

temperatures

• Allocate cooling

resources

• Dynamically manage

cooling units

• Optimize temperature

distribution


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Typically results in 40%

cooling energy savings

DATA CENTERS

CRIME OF ENERGY MANAGEMENT | 35

MEASURE • Instrument the environment

MODEL • Profile the dynamic system

• Simulate effect of changes

MANAGE • Optimize closed-loop control

• Modify infrastructure

DATA CENTERS


Site Name

Square

Feet Sensors CRAHs

kWh

Savings

Dollar

Savings

Cooling

Reduced

Office of Technology Services, Gold Camp 40,000 495 23 484,174 $48,417 19%

Employment Development Department 12,500 63 5 433,049 $43,305 54%

Franchise Tax Board LA Data Center 12,000 126 15 697,045 $69,705 78%

Department of Water Resources 5,300 53 6 288,348 $28,835 40%

Department of Trans. (Caltrans), 2nd Floor 4,000 44 4 149,555 $17,947 64%

Secretary of State 2,700 32 5 37,084 $3,708 30%

Department of General Services, Ziggurat 2,500 41 4 84,134 $11,358 50%

Department of Trans. (Caltrans), 9th Floor 667 31 3 140,135 $16,816 64%

Totals 79,667 885 65 2,313,524 $240,091 41%

8 State of California Data Center Results

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DATA CENTERS

• Reduced energy consumption of eight data centers by more than 2.3 million kWh

• Projecting over $240,000 in annual savings

• Results achieved at diverse set of data centers

– Demonstrates the power and flexibility of intelligent energy management

• Works in big or small, old or new data centers


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8 State of California Data Center Results

Arenas and Stadiums


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ARENAS AND STADIUMS

• Way overprovisioned

– Designed for fully occupied on hottest day of

the year….+30% more

• Extremely dynamic environment

– Basketball practice vs basketball game

• Single large open space makes monitoring

easy and control simple


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ARENAS AND STADIUMS


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“One second ROI”

ARENAS AND STADIUMS

• 23 wireless temperature sensors

• 1 gateway to collect temperature information

• 1 server that operates intelligent control

• 4 wireless control modules for VFD


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ARENAS AND STADIUMS


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Processing and Manufacturing


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PROCESSING PLANTS

• Previous experience

– Waste water, dairy, recycling, waste

management, cold storage, iron ore processing

plant, mill/lathe manufacturing plant

• Electric motors consume the most energy

• Significant heating costs for sites in cold

climates


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PROCESSING PLANTS

• Motor opportunity for savings

– Turn off production lines (motors) when not in

use

• Use sensors to cycle equipment on/off

– Replace old motors with high efficiency,

especially if they operate 24/7

– Consider VFDs if motors do not need to

operate at 100% all the time


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PROCESSING PLANTS

• Equipment replacement opportunities

– Replace old antiquated equipment with newer

more efficient equipment

– Buy equipment that can streamline process or

operation

• ActOnEnergy may be able to provide incentives

based on incremental energy savings when

selecting premium efficiency equipment over

standard equipment


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PROCESSING PLANTS

• Heating savings opportunities

– Electric heating = BAD

• Expensive and increased demand charges

– Improving insulation is the lowest hanging fruit

• Add air curtains loading docks

• Repair holes metal siding, roof

• Add insulation where possible

– Turn it off when you are not using it


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HOW TO START NEXT MONDAY

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WHAT TO DO NEXT MONDAY

• Measure energy from top down

– Facility Energy: electric bills, borrow monitoring

equipment, ask utility for data

– End Use Energy: lighting, processing rooms, IT

equipment

– Equipment Energy: Individual cooling units,

single production line, single piece of equipment


NEXT STEPS

• Graph to identify patterns


vs

NEXT STEPS

• Ask questions and point to areas for potential

improvements

– “Maybe our fans don’t need to run at 100%

during this event”

– “Why are we heating overnight?”

– “Why does this production line use more energy

than this one?”


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NEXT STEPS

• Find solutions to achieve goals

– Install intelligent cooling control for data centers

– Implement wireless monitoring and control for

AHUs in arena or stadium

– Control production lines based on sensors or a

time schedule instead of running 24/7

– Your utility is out to help, ask about incentive

programs


ACTONENERGY INCENTIVES

• Available cash incentives (based on annual

energy savings)

– Electric Savings

• Lighting $0.06/kWh

• HVAC $0.08/kWh

– Gas Savings

• All $1.20/therm


NEXT STEPS

• Don’t forget to promote!


05/14/2012

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QUESTIONS

Questions?


Dan Mascola

Blog: www.dchuddle.com

Twitter: @dchuddle

http://www.dchuddle.com

PowerPoint Presentation · 2016-05-18 · ARENAS AND STADIUMS • Way overprovisioned –Designed...

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