environmental product declaration...declaration number: epd-tra-2011111-e auxiliary sub-stances /...

Declaration number

EPD-TRA-2011111-E

Institute for Construction and Environment

www.bau-umwelt.com

Trane Centrifugal Chiller2500 Ton

Trane

Environmental Product Declaration A c c o r d i n g t o I S O 1 4 0 2 5

Summary

EnvironmentalProduct-Declaration

Institute for Construction and

Environment www.bau-umwelt.com

Program holder

Trane

3600 Pammel Creek Rd

La Crosse, WI 54601 USA

Declaration holder

EPD-TRA-2011111-E Declaration number

Declared building product

This declaration is an environmental product declaration according to ISO 14025 and describes the specific environmental impacts of the mentioned centrifugal chiller. It is supposed to foster the sus-tainable development of environmentally and health friendly construction. All relevant environmental data is contained in this validated declaration.

The declaration is based on the PCR document, “Water-cooled chillers,” year 2011.

Declared Building Products

This validated declaration entitles the usage of the label of the Institute for Construction and Envi-ronment. This exclusively applies to the mentioned products, three years from the date of issue. The declaration holder is liable for the basic information and verifications.

Validity

The declaration is complete and contains in detailed form: - Product definition - Raw materials - Description of product manufacture - Results of the life cycle assessment

Content of the declaration

July 1, 2011 Date of Issue

Signatures

Prof. Dr.-Ing. Horst J. Bossenmayer (President of the Institute for Construction and Environ-ment)

This declaration, and the rules on which it is based, have been verified by the independent Advisory

Board (SVA) according to ISO 14025. Verification of the Declaration

Signatures

Prof. Dr.-Ing. Hans-Wolf Reinhardt (Chairman of the inde-pendent advisory board)

Dr. Eva Schmincke (Verifier appointed by the Advisory Board)

Summary

EnvironmentalProduct-Declaration

A centrifugal chiller is a machine that removes heat from a liquid via a vapor-compression cycle. The cooled liquid can then be circulated through a heat exchanger to cool air or equipment as required. The chiller utilizes the vapor-compression cycle to chill water and reject the heat collected from the chilled water plus the heat from the compressor to a second water loop cooled by a cooling tower.

Product description

The function of this chiller is to provide chilled water for cooling a commercial building. Applications

The LCA is performed according to ISO 14040 corresponding to the requirements of the guidelines concerning Type III declarations of the Institute for Construction and Environment. Specific industrial data from Trane as well as data from the data base “GaBi 4” is used as data basis. The LCA com-prises raw material and energy consumption, raw material transports and the actual production phase of Trane centrifugal chillers, as well as its recycling at the end of the life cycle. The LCA applies to the Trane CenTraVac family of chillers (model numbers CVHE, CVHF, CDHF, CVHG, and CDHG) that are manufactured in La Crosse, Wisconsin, U.S.A.

Scope of the LCA

Trane centrifugal chiller

Parameter Unit per ton chill-ing capacity

Product

Primary energy, non-renewable [MJ] 944,859.80

Primary energy, renewable [MJ] 50,586.35

Global Warming Potential (GWP 100 year) [kg CO2-eqv.] 63,572.12

Ozone Depletion Potential (ODP) [kg R11-eqv.] 7.08E‐03

Acidification Potential (AP) [kg SO2-eqv.] 439.02

Eutrophication Potential (EP) [kg PO43--eqv.] 16.09

Photochemical Ozone Creation Potential (POCP) [kg C2H4-eqv.] 21.90

Results of the LCA

Issued by: PE INTERNATIONAL, Leinfelden-Echterdingen

In cooperation with Trane

Tests and verification according to PCR, including test standard and test date. Evidence and verifications

Environmental Product Declaration CenTraVac Chiller

Product group: Water-cooled chillers Issued Declaration holder: Trane 07-01-2011 Declaration number: EPD-TRA-2011111-E

Scope of validity This EPD is valid for the Trane CenTraVac family of chillers (model numbers CVHE, CVHF, CDHF, CVHG, and CDHG) that are manufactured in La Crosse, Wisconsin, U.S.A.

1 Product definition

Product definition A centrifugal chiller is a machine that removes heat from a liquid via a vapor-compression cycle. The cooled liquid can then be circulated through a heat ex-changer to cool air or equipment as required. The chiller utilizes the vapor-compression cycle to chill water and reject the heat collected from the chilled water plus the heat from the compressor to a second water loop cooled by a cooling tower.

Application The function of this chiller is to provide chilled water for cooling a commercial build-ing.

Placing on the market/ Codes of practice

The rating and testing of chillers used in comfort cooling applications are standard-ised according to ARI Standard 550/590-2003, “Performance Rating of Water Chill-ing Packages Using the Vapor Compression Cycle.”

Delivery status, properties

The dimensions of the declared product are: width: 136 11/16 inches; length: 299 inches; height: 134 3/8 inches.

Technical prop-erties

The chilling capacity of this product is 2500 tons. The energy efficiency in the table below is calculated based on different combinations of load % and Entering Con-denser Water Temperature (ECWT), as described in the background report.

kw/ton @ 25% @ 65°F

kw/ton @ 50% @ 65°F

kw/ton @ 75% @ 75°F

kw/ton @ 100% @ 85°F

0.287 0.295 0.411 0.548 For constant-speed started chillers, the evaporator’s pressure drop is 15.04 feet of water, and the condenser’s pressure drop is 9.76 ft of water. For variable-speed started chillers, the evaporator’s pressure drop is 15.05 feet of water and the condenser’s pressure drop is 10.95 ft of water.

2 Basic materials

Declaration of ba-sic materials

The chiller assembly is broken into major assemblies as described below.

Total Lbs

Compressor 29,157

Compressor Install 5,070

Condenser 25,265

Controls 31

Economizer 668

Evaporator Tubes 16,453

Motors 363

Oil Tank 511

Purge 1,290

Shell 1,281

Unit Assembly 919

81,008

The raw materials used in these assemblies are shown in the following figure.



Auxiliary sub-stances / additives

The chiller requires an initial charge of 1.6 lbs R-123 coolant per ton of chilling ca-pacity for a total of 4000 lbs. Additional coolant recharges are also required at a maximum of 0.5% per year (20 lbs / year).

Material explana-tion

The chiller heat exchangers are primarily made of carbon steel sheet with copper tubes used for heat transfer. The compressor is made of cast gray iron components that form the enclosure, with aluminum cast internal components and an electrical motor made from copper wire, electrolytic steel stampings and a steel shaft.

Raw material ex-traction and origin

The major components of the chiller are metals and metal parts that come from the global metal markets. Global averages are used for input materials where possible.

Availability of raw materials

All the materials used in the manufacture of this chiller are available in the earth’s crust. None of the metals or scrap sources are rare or greatly depleted.

3 Product manufacturing

Manufacturing process

The manufacturing of centrifugal chillers in La Crosse, Wisconsin, uses lean Six Sigma manufacturing practices to provide a full range of products from 140 to 4000 tons. All production components arrive when needed (including raw casting, plate steel, copper tubing and labor) to reduce inventory and allow a smaller manufactur-ing footprint, better aligning and minimizing necessary resources to meet customer requirements, including transportation costs and waste, and obsolesce of materials.

Plate steel is flame-cut, rolled, drilled, and sub-arc welded into shells and water-boxes. Gray-iron and aluminum castings are machined and assembled into a com-pressor. These primary components, along with subassemblies (i.e. starters, purges, controls, lubrication system), are assembled using a combination of welding, brazing, bolting, and testing to create the CenTraVac centrifugal chiller.

4 Product installation

Installation Handling recommendations for refrigerants can be found in product and application literature, brochures and data sheets provided directly by suppliers of available from the internet; www2.dupont.com/DuPont_Home/en_US/index.html

Environmental protection

During the entire production process, extra measures are taken to minimize the unintentional release of halogenated refrigerants. These measures are consistent



with those identified in ANSI/ASHRAE Standard 147-2002, Reducing Release of Halogenated Refrigerants from Refrigeration and Air-Conditioning Equipment and Systems.

Packaging The chiller is packaged in a single, large heat-shrink recyclable plastic bag for ship-ping to protect it from damage due to environmental conditions. Packaging is ex-cluded from the scope of the LCA based on the mass cut-off rules.

5 Condition when in use

Use stage Energy consumption of the chiller during its reference service life depends on the application and site-specific use phase parameters.

Energy Consump-tion

In order to determine average annual chiller energy usage for a given region or loca-tion, a life-cycle program was utilized to determine average weighting factors for specific buckets of performance. The four buckets, or performance bins, being util-ized are those defined by AHRI Standard 550/590-2003 and include 100% load at 85°F entering condenser water, 75% load at 75°F entering condenser water, 50% load at 65°F entering condenser water, and 25% load at 75°F entering condenser water. In addition to the percentages, the annual hours of operation were deter-mined. The software that was used to obtain the above mentioned values has been tested in compliance with ANSI/ASHRAE Standard 140–2007. This procedure has been developed to determine the average energy usage impact for a given location, by manufacturer. The values resulting from the calculation are not intended to reflect actual energy usage for specific applications. The intent is to provide the means of having a global and universal method of determined average energy usage of chillers by manufacturer. For specific energy usage and life-cycle evaluation, a complete analysis must be completed for each and every application.

25% @ 65°F

50% @ 65°F

75% @ 75°F

100% @ 85°F

Hours of Opera‐tion

Consumption over 25 yr life [kWh]

Atlanta 0.15 0.07 0.24 0.54 3131 89,675,754

Bangkok 0.01 0 0.05 0.94 4527 152,373,161

Beijing 0.19 0.07 0.3 0.44 2457 67,506,075

Berlin 0.34 0.22 0.31 0.13 1850 41,755,656

Boston 0.25 0.1 0.33 0.32 2034 52,406,010

Buenos Aires 0.24 0.12 0.35 0.29 3361 85,505,941

Cairo 0.17 0.08 0.28 0.47 4108 114,261,453

Cancun 0.01 0.01 0.19 0.79 4382 141,546,816

Capetown 0.22 0.15 0.44 0.18 3799 91,857,446

Caracas 0 0 0.05 0.95 4500 152,198,438

Chicago 0.21 0.09 0.29 0.41 2140 57,604,788

Dallas 0.13 0.06 0.21 0.59 3341 97,022,640

Denver 0.25 0.22 0.34 0.19 2187 52,010,961

Dubai 0.06 0.02 0.27 0.65 4568 139,977,795

Hanoi 0.13 0.02 0.16 0.69 4316 131,392,528

Ho Chi Minh 0 0 0.03 0.97 4500 152,969,063

Hong Kong 0.13 0.05 0.18 0.64 4188 124,791,930

Houston 0.12 0.03 0.19 0.66 3772 113,881,395



Jerusalem 0.18 0.11 0.48 0.23 3040 77,411,700

Kansas City 0.17 0.05 0.19 0.59 2669 77,559,472

London 0.35 0.18 0.32 0.14 1841 41,628,462

Los Angeles 0.22 0.15 0.43 0.19 3859 93,638,635

Madrid 0.29 0.18 0.37 0.16 2605 61,230,525

Manila 0 0 0.04 0.96 4467 151,464,803

Melbourne 0.49 0.16 0.24 0.11 2888 62,588,375

Mexico City 0.14 0.15 0.48 0.23 3677 93,706,047

Miami 0.03 0.01 0.18 0.77 4342 137,722,813

Minneapolis 0.23 0.1 0.36 0.31 1860 48,051,938

Moscow 0.3 0.16 0.38 0.16 1451 34,203,698

Mumbai 0.01 0.01 0.18 0.8 4500 145,743,750

New Delhi 0.13 0.07 0.27 0.53 4175 119,866,859

Ottawa 0.28 0.12 0.32 0.28 1708 42,776,860

Paris 0.29 0.13 0.38 0.19 1999 47,711,133

Perth 0.27 0.15 0.4 0.18 3830 92,106,713

Phoenix 0.13 0.1 0.42 0.35 4152 111,904,185

Raleigh 0.16 0.07 0.26 0.51 2914 82,486,234

Riyadh 0.13 0.08 0.46 0.33 4545 122,376,966

Rome 0.24 0.07 0.26 0.43 3158 85,271,921

San Diego 0.22 0.26 0.31 0.21 4800 114,699,000

San Francisco 0.37 0.26 0.29 0.08 3163 68,384,060

San Juan 0 0 0.13 0.87 4465 147,956,147

Sao Paulo 0.1 0.05 0.39 0.46 4210 119,937,638

Seattle 0.37 0.21 0.29 0.13 1742 39,039,309

Seoul 0.22 0.07 0.26 0.45 2289 62,554,078

Shanghai 0.21 0.03 0.24 0.51 2859 79,916,198

Singapore 0 0 0 1 4500 154,125,000

Sydney 0.23 0.11 0.37 0.29 3851 98,549,497

Taipei 0.12 0.04 0.22 0.63 4277 128,817,894

Tokyo 0.25 0.04 0.28 0.43 2673 72,550,232

Toronto 0.24 0.13 0.4 0.23 1676 41,655,933

Vancouver 0.35 0.22 0.33 0.1 1765 39,246,981

Venice 0.24 0.1 0.37 0.29 2424 62,019,555

Vienna 0.27 0.18 0.37 0.18 1940 46,232,625

Warsaw 0.27 0.16 0.33 0.23 1804 43,562,090

Washington DC 0.2 0.06 0.27 0.47 2431 67,404,033



Environment – health effects

During the entire production process, extra measures are taken to minimize the unintentional release of halogenated refrigerants. These measures are consistent with those identified in ANSI/ASHRAE Standard 147-2002, Reducing Release of Halogenated Refrigerants from Refrigeration and Air-Conditioning Equipment and Systems.

Maintenance Maintenance for this product is described in the CenTraVac Annual Inspection Check List and Report, which can be provided upon request. The checklist covers aspects relating to the compressor motor, starter, oil sump, condenser, control cir-cuits, leak test chiller, and the purge unit.

Reference Service Life

The reference service life (RSL) is 25 years in an outdoor application.

6 Singular effects

Fire Product is inflammable.

Water

Chiller designed with NEMA 4 construction to prevent failure of components from water contact.

7 End of life phase

Reuse The chiller is not reused.

Subsequent use N/A

Closed-loop recy-cling

Metal components of the chiller can be recycled into other systems. Scrap at end of life is modelled as looping back to fill the demand for scrap in the incoming raw ma-terial manufacture. Credit is applied to the environmental profile of surplus scrap based on the average value of that scrap.

Open-loop recy-cling

Scrap at end of life is modelled as looping back to fill the demand for scrap in the incoming raw material manufacture. Credit is applied to the environmental profile of surplus scrap based on the value of scrap methodology described below.

Disposal Product disposal is left to the owner’s discretion.



8 Life cycle assessment

8.1 Information on system definition and modeling of the life cycle

Declared Unit The declared unit refers to “one ton chilling capacity” for a 2500-ton centrifugal

chiller.

System bounda-ries

Assumptions and estimations

The product mix presented is representative of the product range of the plant. For the life cycle assessment, a single product has been modeled to represent the prod-uct family. Regarding power supply, the energy carriers and energy sources used for the production site have been considered. All process waste resulting from pro-duction and finishing is recycled internally.

The end-of-life scenario has been assumed as recycling and has been modeled based on an elementary analysis, according to the average composition of the products.

Cut-off criteria If a flow is less than 1% of the cumulative mass of all the inputs and outputs of the Life Cycle Inventory model, it may be excluded, provided its environmental relev-ance is not a concern. If a flow meets the above criteria for exclusion, yet may have a significant environmental impact, it is evaluated with proxies identified by chemical and material experts within PE. If the proxy for an excluded material has a signifi-cant contribution to the overall Life Cycle Impact Assessment (5% or more of any impact category), more information is collected and evaluated in the system.

Transports The major components of the chiller are metals and metal parts that arrive at the Trane facility via truck and rail. Approximately 80% of incoming parts and materi-als arrive by truck, the remainder come by rail. The average distances for inbound parts by truck and rail are 303.5 miles and 839.5 miles, respectively.



Period under con-sideration

The chiller production is modeled based on a 12-month average from Q4 2009 – Q3 2010 for the site involved in data collection.

Background data For life cycle modeling, the GaBi 4 Software System for Life Cycle Engineering was used /GaBi 2006/. All background data sets relevant to production and disposal were taken from the GaBi 4 software.

Data quality The data was collected under consistent time and methodological boundary condi-tions. All data used is less than 5 years old.

Allocation

Steel, aluminum, cast iron, and copper scrap generated during manufacturing and at End-of-Life were considered valuable co-products, and were addressed with system expansion. To be consistent with the Worldsteel dataset for steel plates, the scrap steel was given a credit based on the ‘Value of Scrap’ model as described in a study of recycling methodologies. This model is also included upstream in the production of other steel parts, which includes scrap input, and is consistent throughout the study. Aluminum, cast iron, and copper scrap were also given credits based on the production of primary metal, less any energy and materials required for remelting / alloying of these secondary materials.

This approach was chosen to ensure that both the use of post-consumer scrap and high collection rates are encouraged.

Information on use stage

Emissions of refrigerant during the use phase are included in this EPD. Also, emis-sions related to the generation and distribution of electricity for product use is in-cluded.

Choice of the end-of-life scenario

The product is assumed to be disassembled and the components separated by ma-terial type. Credits are applied for scrap steel, aluminum, cast iron, and copper.

Credits Credits are applied for surplus scrap steel, aluminum, cast iron, and copper gener-ated during manufacture and at end of life. The credits are calculated based on the ‘Value of Scrap’ methodology used in the creation of upstream datasets.

8.2 LCA Results

Trane Centrifugal Chiller

Product Stage

Construction Process stage

Use stage / operation

Use stage / mainten‐ance

End‐Of‐Life Credits

Unit per ton chilling

capacity

Raw

material supply,

Transport,

Manufacturing

Transport

Construction‐

installation Process

Use

Maintenance incl.

Transport

Repair, Replacement,

Refurbishment, incl.

Transport

Transport

Re‐use/Recycling

Disposal

Credits

Primary energy from non‐renewable re‐

sources [MJ] 991.77 943,985.55 ‐117.52

Primary energy from renewable resources

[MJ] 21.77 50,560.36 4.23

Total mass of Re‐sources (TMR)

[kg] 1,470.53 24,129.44 ‐123.30

ADP excluding re‐sources

[kg Sb eq.] 5.63E‐04 4.06E‐03 ‐4.39E‐05

Mass of secondary material

[kg] 1.25 0.00 ‐2.94

Fresh water utiliza‐tion

[m3] 475,712.54 517,521,497.06 ‐83,099.60

Global Warming Potential

[kg CO2 eq.]

74.65 63,509.01 ‐11.54

Ozone Depletion Potential

[kg R11 eq.]

1.55E‐04 6.93E‐03 1.75E‐07

Acidification Poten‐tial

[kg SO2 eq.]

3.46E‐01 4.39E+02 ‐4.29E‐02

Eutrophication Po‐tential

[kg Phos‐phate eq.]

2.16E‐02 1.61E+01 ‐1.37E‐03

Photochemical Ozone Creation

Potential

[kg Ethy‐lene eq.]

3.09E‐02 2.19E+01 ‐6.24E‐03

Materials for recy‐cling

[kg] 4.14E‐01 0.00E+00 1.02E+01

Hazardous waste to final disposal

[kg] ‐1.19E+00 ‐4.81E‐06 ‐2.24E‐01

Non‐hazardous waste to final disposal

[kg] 1.01E+00 4.79E‐06 2.27E‐01

Radioactive waste [kg] 1.25E+00 ‐2.09E‐06 ‐2.94E+00



Contributing Fac-tors

The graph below shows environmental impacts split out for 25 years of service life. The electricity demand during use dwarfs all other impacts.

Interpretation Because the Use Phase dominates all other impacts by a factor of more than 1000, selected impact categories are shown below without this life cycle phase. The graph below shows that manufacturing energy dominates the cradle-to-gate impacts of the chiller’s life cycle, followed by upstream production of steel and copper. In the graph below, the raw materials are broken out by type (1a – 1f), followed by Trans-port (2), Manufacturing energy (3), and End of Life credits (5).

Transport plays a minimal impact, but the material credits at End-of-Life are sub-stantial. When calculating the credits for recycling of metals after the Use stage, it was assumed that Masdar, being a zero waste city, would reclaim all of the steel, aluminum, iron, and copper. Other materials are assumed to be reused in other product systems, but no credit is applied.



9 Evidence

The manufacturer presents the relevant test certificates to IBU.

10 PCR-document and verification

This declaration is based on the Product Category Rules – Water Cooled Chillers

Review of the PCR-Documents by the Committee of Experts. Chairman of the Committee of Experts: Prof. Dr.-Ing. Hans-Wolf Reinhardt (Stuttgart University, IWB)

Independent verification of the declaration according to ISO 14025:

internal external

Validation of the declaration: Dr. Eva Schmincke

11 References

/Institut Bauen und Umwelt/

Leitfaden für die Formulierung der produktgruppen-spezifischen Anforderungen der Umwelt-Produktdeklarationen (Typ III) für Bauprodukte, www.bau-umwelt.com

/GaBi 4 2009/

GaBi 4: Software und Datenbank zur Ganzheitlichen Bilanzierung. LBP, Universität Stuttgart und PE International, 2001-2009.

Standards and laws

/ISO 14025/ ISO 14025: 2007-10, Umweltkennzeichnungen und -deklarationen - Typ III Umwelt-deklarationen - Grundsätze und Verfahren (ISO 14025:2006); Text Deutsch und Englisch

/ISO 14040/ ISO 14040:2006-10, Umweltmanagement - Ökobilanz - Grundsätze und Rahmen-bedingungen (ISO 14040:2006); Deutsche und Englische Fassung EN ISO 14040:2006

/ISO 14044/ ISO 14044:2006-10, Umweltmanagement - Ökobilanz - Anforderungen und Anlei-tungen (ISO 14044:2006); Deutsche und Englische Fassung EN ISO 14044:2006

Publisher:

Institute for Construction and Environment (IBU) Rheinufer 108 53637 Königswinter Germany

Tel.: +49 (0) 2223 296679 0

Fax: +49 (0) 2223 296679 1

Email: [email protected] Internet: www.bau-umwelt.com

Layout:

PE INTERNATIONAL

Illustration credits:

Trane Trane 3600 Pammel Creek Rd La Crosse, WI 54601 USA