Process Air Compressors, Boilers, and Water Heaters #1h-m-g.com/T24/Process/Process Air Comp Boilers...

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California Statewide Utility Codes and Standards Program

Process Air Compressors,

Boilers, and Water Heaters #1

Energy Solutions

Heschong Mahone Group, Inc.

Portland Energy Conservation, Inc.

Taylor Engineering

May 25, 2010

May 25, 20102011 Title 24 CASE Process Update

2CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM

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Agenda

● 10:00–10:15 Introductions

● 10:15–11:15 Water Heater Standby Loss

● 11:15-11:30 Hot Water Temperature Reset

● 11:30-12:15 Process Boilers

12:15– 1:00 Lunch

● 1:00–2:00 Air Compressors

● 2:00–2:15 Closing Comments

CA Utilities 2011 Title 24 Stakeholder Meeting for Proposed Code Changes



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IOU Support for 2011 Title 24

● The California Investor Owned Utilities (IOUs) are actively supporting the California Energy Commission (CEC) in developing the state’s building energy efficiency code (Title 24)

● Their joint intent is to achieve significant energy savings through the development of reasonable, responsible, and cost-effective code change proposals for the 2011 code update and beyond

● As part of the IOU effort, at the request of the CEC, we are hosting stakeholder meetings to get industry input and feedback on our code change proposals




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Code Change Activity

● 2011 T-24 Base Code (Part 6 of Title 24)

● 2011 Reach Standard (Part 11 of Title 24)

● Green Building Standard – i.e. CalGreen

● Voluntary standards that local governments can

adopt

● Future Codes

● 2014 T-24

● Future Reach Codes




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Requirements for a Successful Code Change

● To be included in the base code, a measure must:● Be cost-effective

● based on the standards-induced additional first cost, maintenance costs, measure life, and energy cost savings

● according to the Time Dependent Valuation (TDV) life-cycle costing methodology and weather data to be provided by the California Energy Commission

● Be possible to implement using equipment that is available from multiple providers or that is reasonably expected to be available following the code change




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Stakeholder Meetings Process

● Minimum of three meetings:

● First: present scope, request data

● Code change direction and possible options

● Methodology

● Best practices, market data

● Second: present findings

● Results of data collection and analysis

● Cost effectiveness

● “Strawman” proposed code language

● Third/final: present proposed code language

● All meetings can be attended remotely




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Outline For Measure Presentations

● Summary of current code requirements

● Typical practice

● Summary of potential code change proposals

● Initial data/findings

● Planned data collection and analysis

● Specific stakeholder requests




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Submitting Comments

● Informal Comment Process

● Comments can be submitted to CASE authors,

substantive comments will be receive responses.

● Questions and responses will not be posted

online, but common or frequent questions will

be communicated as necessary between

stakeholders

● The team will work with stakeholders to resolve

issues as best we can.

● The CEC has a formal comment process during

later stages of the official rulemaking process




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Types of Code Change

● Mandatory Measure: The change would add or modify a mandatory measure

● Mandatory measures must be satisfied whether the prescriptive or performance method is used to show compliance

● Prescriptive Requirement: The change would add or modify a prescriptive requirement that must be met when using prescriptive compliance approach

● When using performance compliance (computer modeling), prescriptive requirements define a standard design (which sets the energy budget) and are not mandatory




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Types of Code Change – Ctd.

● Compliance Option: The change would add or modify a new measure to the list of existing compliance options for meeting the Standards using the performance approach.

● Modeling: The change would modify the calculation procedures or assumptions used in making performance calculations.

● This change would not add a compliance option or a new requirement, but would affect the way that trade-offs are made.




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Schedule: Key Dates

● Mar 2010 - Dec 2010● CEC develop foundation /methodology

● IOUs:● Conduct research, and cost effectiveness analysis

● Present results at stakeholder meetings

● Dec 2010● IOUs finalize code change proposals for submittal to CEC

● Feb 2011● CEC opens Rulemaking for Title 24, develop 45-day language

● June 15, 2011● Title 24 Adoption date

● Jan. 1, 2013● Title 24 Implementation date




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Process - Related CASE Topics for 2011 Title 24 Cycle

● Codes and Standards Enhancement (CASE)

Topics

● Water Heater Standby Losses

● Hot Water Temperature Reset

● Process Boilers

● Air Compressors




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Ground Rules

● For those attending by telephone/web● Please DO NOT place your phone on HOLD

● We do not want to hear your hold music

● Please mute your microphone, unless you want to speak● Ask questions/comment by “chat” or by voice● Call will drop at 12:30 – please hang up and re-dial in

● We want to hear your concerns● Opposing viewpoints are encouraged● We are seeking information, not resolution

● Time is limited● Raise your hand and be acknowledged by presenter● Clearly state your name and affiliation prior to speaking● Speak loudly for the people on the phone

● Minutes and presentation material will be available online – we will distribute link


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Water Heater Standby Loss Stakeholder Meeting #1

Heschong Mahone Group, Inc.

May 25, 2010



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Water Heater Standby Loss



● Summary of potential code change

proposals


● Potential code change proposals






WH2 Standby Loss

Current Code Requirements

● Current Code Requirements● Title 24 water heater efficiency requirements follow federal standards, which preempt CA to have more stringent standards

● Standby stack heat loss in atmospheric combustion gas storage water heater is included in Energy Factor (EF)

● Changing market conditions● New federal regulations for residential water heaters were passed this year

● Residential water heaters– 20 to 100 gallon capacity

– Less than 75,000 Btu/hr input

– Efficiency measured by EF

● Commercial water heaters– Greater than 75,000 Btu/hr input

– Efficiency measured by Thermal Efficiency and Standby Loss




WH2 Standby Loss

Typical Practice

● Water heating represents more than 30% of total residential building energy use

● Single family homes in California typically use a 40 or 50 gallon natural draft gas water heater, more tankless water heaters are used

● Multi-family and hotel/motel buildings use commercial grade water heaters or boilers

● Other non-res buildings used a variety of water heaters based on hot water demand

● Gas water heaters with low standby loss● Forced draft water heaters

● Tankless water heaters

● Condensing water heaters

● Water heaters with integral flue damper




WH2 Standby Loss

Potential Code Change Proposals

● Require a flue damper to be installed as part of the flue exhaust system to reduce stack heat loss

● For both res. and non-res. buildings

● Availability of third-party flue dampers

● Feasibly of working with water heater controls

● Compliance options: high efficiency water heaters

● Require a 110V electric outlet to be installed in the water heater closet or near water heater in garage

● Require PVC exhaust pipe and condensate drain to be installed to accommodate forced draft or condensing water heaters

● Modify ACM to include the benefit of third party flue dampers




WH2 Standby Loss

Potential Code Change Proposals – Reach Code

● Require water heaters to be equipped

with flue dampers, or to be:

● Force draft type

● Tankless water heater

● Require water heaters to have standby

loss within limits that are equivalent to

those with integral flue dampers




WH2 Standby Loss

Initial Data / Findings – Energy Impact

● In a 40-gal WH, stack heat loss represents● ~43% of the total heat loss or

● 17% of total WH energy consumption


From a TANK simulation study performed by Peter Biermayer and Jim Lutz of LBNL



WH2 Standby Loss

Initial Data / Findings – Energy Savings

● ~24 Therms/year for a 40-gal water

heater

● EF = 0.60, RE = 0.78

● Flue damper effectiveness = 0.65

● Savings for commercial water heaters

depend on standby loss ratings

● ~30 Therms/year for a 100-gal 200kBtu

WH




WH2 Standby Loss

Initial Data / Findings – Availability & Feasibility

● Water heaters with integral flue dampers are

available

● Bradford White res models with 0.67 EF

● After market flue dampers are mostly for

boilers, where connections often already

exist for easy retrofits

● Installation feasibility

● Reliability of buoyancy driven flue dampers

● Need to connected to the ignition circuit




WH2 Standby Loss

Potential Code Change Proposals Update

● Section 113 mandatory requirements for all

buildings

● A 110V electric outlet to be installed in the water

heater closet or near water heater in garage

● PVC exhaust pipe and condensate drain to be

installed if natural gas stud is installed

● Modify Res and Non-Res ACM to include the

capability to calculate energy savings of

after market flue dampers




WH2 Standby Loss

Planned Data Collection and Analysis

● Coordinate with SEMPRA Emerging Technology Program to

● Identify flue damper products

● Perform flue damper test and energy savings analysis

● Analyze energy savings potential of flue dampers in multifamily applications

● Perform field study to evaluate effectiveness and energy savings of electric driven flue dampers in multifamily applications

● Investigate water heater models to develop ACM algorithms that capture flue damper savings




WH2 Standby Loss

Specific Stakeholder Requests

● After market flue damper products and costs (including installation costs)

● Technical information on flue damper effectiveness (savings, maintenance costs, etc.)

● Incremental costs of water heaters with flue dampers

● Installation costs of PVC exhaust pipes

● Product development plans




WH2 Standby Loss

QUESTIONS & COMMENTS

??


Yanda ZhangHeschong Mahone Group, [email protected]

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Chilled and Hot Water Temperature Reset ControlsStakeholder Meeting #1

Taylor Engineering

May 25, 2010




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Chilled and Hot Water Temperature Reset Controls

Current Code Requirements and Proposed Change gray [delete] /underline [add]

● 144(j)1: “HVAC chilled and hot water pumping shall be designed for variable fluid flow…”

● “Chilled and Hot Water Temperature Reset Controls. Chilled and hot water systems with a design capacity exceeding 500,000 Btu/hr supplying chilled or heated water (or both) shall include controls that automatically reset supply water temperatures as a function of representative building loads or outside air temperature.

● EXCEPTION to Section 144(j)4: Hydronic Chilled water systems that use variable flow speed drives to reduce pumping energy in accordance with Section 144(j)1 144(j)6.”

● 144(j)6: CHW pumps over 5HP shall have VFDs…the pressure shall be reset by valve position.




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History

● The CHW/HW temperature reset

controls have been in Title 24 since

2005

● The same requirements are in ASHRAE

90.1-2010




3030


Rationale – Hot Water

● HW temperature reset always reduces boiler energy and piping losses and always reduces total energy, especially for condensing boilers

● HW temperature reset can increase HW pump energy if the pump has a VFD. (VFDs are not cost effective or required on hot water pumps). Even if the HW pump has a VFD, increasing HW pump energy decreases boiler energy (opposite of CHW pumps!) so HWST reset always makes sense

● Temperature reset is low/no cost – it requres a minor amount of programming but no additional hardware




3131


Rationale – Chilled Water

● Variable flow is required on most CHW and HW systems

● VFDs are required on many CHW pumps but not on any HW pumps

● For CHW systems with VFDs the options are to reset pressure setpoint and/or temperature setpoint

● Resetting pressure will always reduce total energy but will not necessarily save as much energy as temperature reset

● The converse is not necessarily true: resetting temperature could increase total energy in some scenarios. This is why pressure reset is required but temperature reset is not required.

● For CHW systems without VFDs there is no pressure reset● Resetting the temperature will result in a tiny increase in pumpenergy for variable flow systems (pump rides out on curve) but will always reduce total energy due to reduced chiller lift

● The CHW exeption for variable flow was likely a mistake caused by 90.1 language that lumps variable flow and variable speed in the same section




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Future CHW Reset Changes?

● Our recent analyses show that CHW temperature reset saves more than pressure reset unless the pump head is unusually high● Temperature reset is particularly important for waterside economizers

● We may want to:● Always require temperature reset and require pressure reset for high pump head

● Always require both (like air handlers)

● The users guide should discuss combined sequences




3333



??Jeff SteinTaylor [email protected]

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Process BoilersStakeholder Meeting #1

Portland Energy Conservation, Inc.

May 25, 2010




3535

Process Boilers

Current Code Requirements

● Title 24 historically has not regulated process loads

● Process boilers regulated if also serving domestic hot water or space heating




3636

Process Boilers


● Code change options (mandatory)

● Flue damper

● Electronic parallel positioning control

● Electronic parallel positioning with oxygen trim control

● Variable frequency drive on combustion air fan




3737

Process Boilers


● Determine effect of new air quality regulations on measures

● Rough estimates of energy savings via spreadsheet

● Determine energy savings via field monitoring and analysis

● Determine incremental measure costs




3838

Process Boilers

New Air Quality Regulations

● At least 3 air districts have recently adopted more stringent NOx regulations

● Bay Area

● 5-20 MMBtuh/hr: 15 ppm (7/2008)

● 20-75 MMBtu/hr: 9 ppm

● San Joaquin Valley

● 5-20 MMBtu/hr: 9/6 ppm (2012/2014)

● >20 MMBtu/hr: 7/5 ppm (2010/2014)

● South Coast

● 5-75 MMBtu/hr: 9 ppm (1/2013)




3939

Process Boilers

New Air Quality Regulations

● At least 3 air districts have recently adopted more stringent NOx

regulations

● Represents 75% of California installations

● (Payroll, # businesses as proxy)

● Driven by ozone standard non-attainment




4040

Process Boilers

California Air Districts




4141

Process Boilers

California Nonattainment Area Classification: Ozone 1-hour Standard




4242

Process Boilers

Compliance Methods for Air Quality Regs

● Pay a fine instead of complying

● Replace the entire boiler

● Selective catalytic reduction

● Ultra low NOx burner

● Forced draft

● Parallel positioning controls




4343

Process Boilers

Energy Savings Estimates

● Boiler permits for new installations and replacements

● NOx regs apply to specific ranges of boiler sizes

● Knowing the sizes of new boilers by hear, then the # installed by NOx level

● 20% of boilers serve both a process + space heating/DHW load

● 71% of boilers are low NOx or ultra low NOx burners and thus come with PP controls

● 75% load factor

● 330o F stack temperature

● 6-7% O2 setpoint for typical boiler installation

● 5% O2 setpoint (PP) and 3% (O2 trim)




4444

Process Boilers

Energy Savings Estimates

Measure Low High Low High

Flue Damper 1,845 6,341 $1,107 $3,805

Parallel Positioning 110,349 277,934 $66,209 $166,760

Parallel Positioning plus O2 Control 327,821 495,406 $196,693 $297,243

Combustion Fan VFD 1,076,893 2,153,786 $161,534 $323,068

Assumed Energy Costs

Natural Gas $0.60 /therm

Electricity $0.15 /kWh

Energy Savings Estimate

therms/yr

Cost Savings Estimate

($/yr)

kWh/yr $/yr




4545

Process Boilers


● Cost information for each measure

● Recruiting sites for field tests




4646

Process Boilers


??Matt [email protected]



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LUNCH BREAK

Process Air Compressors, Boilers, and Water Heaters:

Title 24 Stakeholder Meeting #1

Conference Call Will Resume At 1:00

please hang up and re-dial the same number:Dial-in Number: 1-702-835-5019

Participant Access Code: 61316#


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Air Compressors Stakeholder Meeting #1

Energy Solutions

May 25, 2010




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Air Compressors


● Summary of potential code change

proposals



● Potential code change proposals






5050

Air Compressors

Current Code Requirements – Title 24

● Process loads, including compressed air systems, are excluded in Title 24 2008

● Defined by Title 24 as: an activity or treatment that is not related to the space conditioning, lighting, service water heating or ventilating of a

building as it relates to human occupancy




5151

Air Compressors


● Performance metric or set of system

design guidelines for compressed air

systems

● Requirements for smart system

controls on multi-compressor systems




5252

Air Compressors

Typical Practice

● Multi-compressor systems are common● (>80% of systems in PG&E Territory)

● Running 80+ hours/week, often at part load conditions

● System-wide efficiency not always considered

● Existing systems may be pieced together over time

● Controls often applied at individual compressor, not system level

● System modifications may be perceived as a risk to system reliability




5353

Air Compressors

Initial Data / Findings

● DOE Industrial Assessment Centers

Audits of small- to medium-sized

industrial facilities

● Average projected system savings of 15%

with <2 year payback

● Many case studies identify savings in

range of 30-60%




5454

Air Compressors


● Performance metric or set of system

design guidelines for compressed air

systems

● Consider sizing and choice of

compressors, storage tanks, and other

system components

● System layout considerations

● Distribution system considerations

● Leak prevention and detection




5555

Air Compressors


● Require smart controls on multi-

compressor systems

● Monitor system demand and choose the

most appropriate combination of

compressors to meet the current load




5656

Air Compressors


● Identify system design and sizing guidelines

and control options that can be

incorporated into Title 24

● Energy savings and cost analysis for

proposed options

● Evaluate energy savings using AirMaster+




5757

Air Compressors


● Current design practices

● Pricing information

● Exceptions or issues with requiring controls

on system modifications

● Individuals or groups who might be able to

provide additional input




5858

Air Compressors


??Megan Johnson Energy [email protected]

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