qiagen sciences germantown, maryland joseph p. diienno mechanical option the pennsylvania state...

Slide 1United States Manufacturing and Research Facility
Feasibility of Energy Recovery in Conjunction With The Application of A Redesigned Central Cooling And Heating Plant
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Germantown, Maryland
United States Manufacturing and Research Facility
Outline
Introduction/Background
Project Team
CM: Whiting-Turner
Outline
Existing Overall Conditions
Size: 213,000 Ft2
Cost: $52.5 Million
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Building 2
Building 1
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Existing Mechanical Conditions
5 – 100% Outdoor air units (4,770 to 18,105 CFM)
Heating Plant
2 – 400 GPM shell and tube HX
Cooling Plant
Primary-secondary distribution
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Outline
Problem Statement
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Problem Statement
No approach for demand reduction
Existing Chiller Plant
Outline
Energy Recovery System (ERS)
4 existing 100% outdoor air units modified with total energy recovery wheels
SEMCO TE3 EXCLU-SIEVE® Total Energy Wheels selected
Cross-contamination issues
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ERS Energy Analysis
Carrier’s Hourly Analysis Program (HAP) V4.10
Peak cooling load reduced from 1,045 tons to 885 tons, a reduction of 160 tons
Peak preheating load reduced from 7,015 MBH to 4,650 MBH, a 2,365 MBH reduction
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ERS First Cost
Cost information was obtained from Spencer Goland at Rotor Source, Inc.
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Outline
Central Plant Redesign
Central Plant Redesign Modeling
Correction factors based on chilled water and condenser water temperatures
Regression coefficients
Capacity correction
Efficiency correction
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Linear regressions for each constant range on plot
Condenser water temperature is a function of range and wet bulb temperature
Curves for full and half speed
Marley Cooling Tower Curves
Affinity laws for variable speed pumping
Head is function of flow rate and motor speed
Bell & Gossett Pump Curve
Gas-fired absorption chiller-heater modeling
Chiller-heaters can provide simultaneous heating and cooling
York YPC double-effect absorption chiller-heater model
Curve fit part load performance charts provided by York for individual and simultaneous operation
Individual Performance (EES)
Simultaneous Performance (EES)
Individual Performance (York)
Simultaneous Performance (York)
Central Plant Redesign Energy Analysis
EES produces hourly energy consumption for central plant components
Microsoft Excel is used to calculate energy costs
Utility rates are taken from service providers
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Central Plant Redesign Energy Analysis
Peak demand kW reductions
Central plant gas usage
kW Demand charge reductions
Total Annual Energy Costs
Central Plant Redesign First Cost Analysis
First cost information for chillers from Jim Thompson at York International
R.S. Means
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Outline
Electrical Analysis
Why look at the electrical system?
2 direct points of connection on main switchgear #2 for existing electric driven chillers
Existing electrical loads on switchgear #2
Power Panel PP4
Serves 4 Emergency Motor Control Centers (EMCC)
Spare connection
Feeder sizing done for each case
Calculations done as per NEC standards
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Electrical Analysis
Case C reduces load by 558 kVA
2500 kVA transformer downsized to 2000 kVA
$6,015 savings
Outline
Structural Analysis
Cooling tower framing
Reinforcing for temperature and shrinkage
Absorption chiller-heater foundation design
Foundation needs to support equipment operating weight
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Structural Analysis
Design Parameters
ACI 318-02
Case A centrifugal chiller foundation
Use 36” depth as in existing building
2 chillers weighing 23,400 lbs each
Case C absorption chiller-heater foundation
Use 12” depth
Chiller-heater foundation depth reduced 24” from centrifugal chiller foundation despite weight increase of over 42,000 lbs
Reduced depth saves $1,840 compared to base building and Case A foundations
Concrete costs
Outline
Life-Cycle Cost Analysis
Used to determine most attractive redesign option
First cost information combined with annual energy costs calculated in central plant redesigns
First costs for ERS design, central plant equipment, structural and electrical redesigns
Analysis Method
NIST Energy Price Indices
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Result of reduced annual energy costs
$864,475 savings over base building
$230,756 savings over Case A redesign
Case A redesign has instant payback
Case C payback; 9 months
Case C net savings over Case A; $133,132
Difference in LCC savings and first cost savings of 2 cases
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Outline
Conclusions and Recommendations
Energy Recovery System Design
Effective response to high energy consumption of 100% outdoor air units
Decreases size of central cooling and heating plant
Central Plant Redesign
Case B central plant first cost and required area too high; not a feasible option
Cases A and C both provide significant life-cycle cost savings
Case C hybrid plant shows best annual energy costs
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Conclusions and Recommendations
Short payback period attractive to owner
Highest net savings of all options evaluated
Flexibility of using either gas-fired chiller-heater or electric driven centrifugal as primary chiller
Future electric utility rates may be more or less favorable
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Acknowledgements
James D. Freihaut, Ph.D.
Jim Thompson – York International Corporation
Spencer Goland – Rotor Source, Inc.
Cindy Cogil – Smith Group
5th Year AE Students
Family, Friends, and People I Forgot
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Questions?
Thank You For
ERS Wheel Selection
SEMCO provided performance charts used to select proper wheel size
Selection based on supply and return air quantities
Return air from general room exhaust, not fume hoods
Optimum face velocity of 800 FPM across wheel
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ERS Performance
3Å Molecular Sieve Desiccant
Adjustable Purge Air Section
Energy Recovery System
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Electrical Analysis
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Electrical Analysis
kVA demand is calculated for load on switchgear
NEC Table 430-150 used to determine the full load current for the motors connected to EMCC’s
Feeder sizing done for each case
NEC Table 310-16 used for wire ampacity
Branch Conductor
NEC 430-22 D at 125% of the full load current
Overload Protection
NEC 430-31 and NEC Table 430-152 ; time delay fuses @ 175% FLC
Disconnect
Grounding sized according to NEC Table 250-94
Conduit sized according to NEC Chapter 9
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Structural Analysis
Reinforcing design
Chapter 7 specifies minimum area of steel for shrinkage and temperature
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Structural Analysis
Chapter 11.12 – Special provisions for slabs and footings
Chapter 15.4 – Shear in footings
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Structural Analysis
Flexure check
Chapter 12 – Development and splices of reinforcement
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Structural Analysis
Chapter 15.5 – Shear in footings
Chapter 11.12 – Special provisions for slabs and footings
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First cost information
Manufacturer cost data
Equipment
Description
Cost ($)
Quantity
Total ($)
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
January
February
March
April
May
June
July
August
September
October
November
December
Month
Plant Demand Charge Comparison
Plant Gas Usage Comparison
Building
Model
200
32
577
8
147.5
39,288
77,093
200
32
577
8
147.5
39,288
77,093
200
32
443
8
123.5
30,328
62,118
14,975
Base Building
Case A
Case B
Case C
Total Central Plant First Cost Comparison
Base Building
Case A
Case B
Case C
a = Depth of Equivalent Rectangular Stress Block
f
prime,c
V
u
a = Depth of Equivalent Rectangular Stress Block
f
prime,c
Reinforcing
Load Factor
Foundation
Heat Exchanger
400 GPM
39,288.00
1.00
39,288.00
$77,093.00
Heat Exchanger
400 GPM
39,288.00
1.00
39,288.00
$77,093.00
Heat Exchanger
400 GPM
30,328.00
1.00
30,328.00
$62,118.00
Costs
Equipment
Description
Heat Exchanger
400 GPM
39,288
77,093
39,288
77,093
30,328
62,118
14,975

qiagen sciences germantown, maryland joseph p. diienno mechanical option the pennsylvania state...

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