Innovative Technology Drives Real Results Curt Sawan Red Lobster Greg DuChane Trane Steve Brown - LC Systems Presenter Introductions 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 What are We going to Learn Today? Curt Sawan 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 1
Background & HVAC Issues History of Red Lobster Restaurant Clarksville, IN Building Design (Dining 40 Tons Total) 1. Three Dining Room Rooftop Units (15, 15 & 10 Ton) 2. Single Thermostat per Rooftop Unit 3. Sequential Compressor Staging Inherent Issues 1. Inadequate Compressor Run Times Oversized 2. Coverage Area Too Large for Single Thermostat 3. Outdoor Air Introduction during Normal Operation Standard Unit Short Cycling Background & HVAC Issues Problems Encountered Guest Comfort High Humidity Mold Employee discomfort Building Air Balance (Negative Pressure) Red Lobster Moisture Issues High Indoor Relative Humidity 2
Red Lobster Moisture Issues High Indoor Relative Humidity HVAC Design Layout Past Experiences Kitchen Other buildings with same design Current 10 Ton equipment asset 15 cost Ton and design Unit Unit Age Lobby Sizing Raised Deck Ability to perform as needed 10 Ton Humidity Control 15 Ton Unit Energy Unit efficiency Main Dining 15 Ton Unit Implication for future retrofits Ductwork Remodels Total Outside Air Building Pressure: +619 CFM 3
Moisture in Outdoor Air 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! F DB Dry Bulb Temperature (F) F WB Wet Bulb Temperature (F) RH Relative Humidity (%) Facts of Moisture in Outdoor Air 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/hr gal/hr = 43.1 lbs/hr / 8.33 lb/gal 5.2 Gallons per Hour! Outdoor Air Management 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? 4
Considerations for resolution Hood operations & Performance Restaurant Operations RTU Dehumidification Options available Past & Present Retrofit current equipment APR Device Add Dehumidifier(s) Hot Gas Reheat Other Options? What about energy efficiency? Must be another option? Future energy consumption & Green Buildings What new technology is out there to reduce energy but still get results? New Technology Introduction Greg DuChane 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 5
Red Lobster HVAC Test Layout 15 Ton High V3 (New) 10 Ton High HGRH (New) 15 Ton Standard (Existing) 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 Results Part Load Days & Temperature Variance Night Unoccupied Night Cleaning 6
Red Lobster System Status Dining Area Occupied Dashboard Red Lobster Guest Comfort Outdoor Air Temp: 60 85 F 72 F 35% OCCUPIED OCCUPIED OCCUPIED Variable Speed T: Hot Gas Reheat T: Std. Efficiency T: Variable Speed RH: Hot Gas Reheat RH: Std. Efficiency RH: 72 F Avg. (74 68 F Range) 72 F Avg. (74 70 F Range) 72 F Avg. (74 70 F Range) 40% Avg. (55 30% Range) 35% Avg. (50 30% Range) 45% Avg. (50 30% Range) Red Lobster Guest Comfort Observations 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 7
Red Lobster Guest Comfort Issues & Head Winds 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 Variable Speed Technology Compressor, Indoor Fan & Condenser Fan Benefits of Variable Speed 8
Red Lobster System Status Dining Area Occupied Dashboard Variable Speed Vs. HGRH Heat 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 Dining Area Load & Energy Calculations October Actual EMS 9
3 RTU 12.5 Ton Dining Roof Sweep 2.1 Years Var. Speed Problem Statement Restaurant was Experiencing High Humidity & Difficulty Controlling Building Moisture Problem Solution Rooftop HVAC Units with Hot Gas Reheat or Variable Speed Results Variable Speed Rooftop Units Provide 2.1 Year Payback Saving Energy & Providing Comfort & Humidity Control Alt. 1: High Efficiency Atl. 2: High Eff. Hot Gas Reheat Alt. 3: High Eff. Variable Speed Lessons Learned 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 Live Data 10
Tricks of the Trade Yes We are Geeks! Airflow Measurement Smart Phone Interface Temperature & RH Data Logging Pocket Temperature & RH Sensor Questions? Curt Sawan Red Lobster Facility Manager Greg DuChane Trane Retail Restaurant National Accounts Presenter Introductions Airflow Testing Method of Test Update Steve Brown LCSystems President, LCSystems, Inc. ASHRAE TC 5.10 Past Chair 11
p st 2001.02 RFMA 2016 Annual Conference March 13 15, 2016 TAB Ports - CKV Air Balance RELIABLE - ACCURATE - EASY KVE-10 T.A.B. Test & Balance Ports 0.50 0.30 [''WC] 0.20 0.10 1000 2000 3000 qv [cfm] EASE OF BALANCING. FIELD SYSTEM FOR BALANCING AIR FLOW RATES ASHRAE Research MOT Evaluate Field Performance of CKV Systems Qmeasure (SCFM) Cyclone Filter Results 4000 3500 3000 2500 2000 1500 1000 500 0 0 1000 2000 3000 4000 Qactual (SCFM) 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! ASHRAE Research MOT Evaluate Field Performance of CKV Systems Perimeter Results Qmeasured 3500 3000 2500 2000 1500 1000 500 0 0 500 1000 1500 2000 2500 Qactual 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 Most Hand Held Devices Report Supply Readings that are HIGH! 12
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 4500 4400 4000 4000 3600 3500 3000 2500 2000 3200 3520 2880 1520 Exhaust MUA Building 1500 1000 800 1040 500 0 Design Hand Held Reading Field Adjusted Exhaust Read 10% Under Design & MUA Read 10% Over Design Field Adjusted = Building Supply 90% over design! Conclusions Hood and Fan Pressure TAB Ports Easy to Use High Degree of Air Balancing Accuracy Customer tool Maintenance Check Performance Update Require Manufacturer s Certification 13
Questions? Steve Brown LC Systems President 14