why retrofit your aging supermarket refrigeration ......• copeland digital technology is...
TRANSCRIPT
Why Retrofit Your Aging
Supermarket Refrigeration
Architecture?
E360 Webinar • August 13, 2019
Andre PatenaudeDirector — Solutions IntegrationEmerson
Speaker
2
Andre Patenaude, C.E.T. Director — Solutions Integration
Emerson
Andre is responsible for supporting system-related innovation and leveraging Emerson’s global cold chain to drive adoption of integrated solutions in North America. He most recently led marketing efforts pertaining to Emerson’s food retail and chiller markets. Prior to that, he had managed Emerson’s global CO2 development.
Andre has more than 34 years of industry experience in sales, marketing, training and business development of HVACR system architectures and applications with compression and component technologies. He is a certified Mechanical Engineering Technologist C.E.T. (since 1984), and is a member of ASHRAE, RSES and OACETT.
Technology Plays a Critical Role in Solving the
Industry’s Need for Food Safety and Quality
Harvest Processing Transportation Distribution Food Retail,
Foodservice
Key Technologies
• Compression/Systems
• Temperature Probes/Sensors
• Loggers/Trackers
• Connectivity Services
• Blockchain
Food Safety and Quality Needs
• Temperature Monitoring
• Verification Data
• Supply Chain Traceability
• Real-Time Insights
• Reporting and Documentation
Consistent temperature controlHandling
TransportationRegulatory requirements
MultipleplayersIntermediaries
Complexity
Customer Pain Points
E-commerce
TCO
Single view into my operationsLast-Mile Challenge
3
Why Is Power Management Important?
4
Energy and Power
FMI Energy SD 2018, Axiom Exergy
5
Super-peak Pricing
Summer super-peak pricing is in effect from June through
September on weekdays between 2 and 6 p.m.
Super-peak charges are significantly higher than supply charges
during the rest of the day. Save by opting to power down during
super-peak periods.
Time-of-Use RatesTiming is everything. Under our time-of-use rate, you’ll
pay less during off-peak periods than you would
under our standard small commercial or residential
rates, and more during peak and summer super-
peak times. See our time-of-use rate guides to learn
how much you and your business can save if you limit
energy use during peak and super-peak periods.
6
Peak Day Pricing combines a time-of-use
(TOU) rate with Peak Day Pricing Event
Day surcharges.
• There are 9 to 15 Peak Day Pricing “Event Days”
per year.
• An Event Day surcharge is added to the
regular TOU rate during peak hours from
2–6 p.m.
• Rates are discounted at all other times from May
1 to October 31.
Time-of-Use Rates
7
8
Trends and Drivers in the Energy Industry
9
Energy markets and demand response programs can generate substantial revenue for participants.
• Rise of renewables
and energy storage
• Time-of-use rate
structures
• Beneficial electrification
• Shift from lighting
rebates
ISO communicates that price is
about to increase from $0.1/kWh
to $1.0/kWh, unless 100 MW is
removed from the system.
Virtual Power Plant Scenario
Fundamentally, to enable transactions we must
commingle energy + information and assign value.
I’m a hotel with a big conference
underway. I need maximum cooling
for my building. I’m looking to buy
your additional load reduction to
avoid price increases.
I’m a big-box store, with variable-speed fans on
my RTUs. I can run those fans at somewhat lower
speeds for 10 minutes and “sell” you the load
reduction. It will make no noticeable difference
to my customers, and I can make some money
(part of the price increase the other customer
is avoiding).
1
2
3
• Example illustrates
concept of “across the
meter” coordination
• “Real-time” utility
pricing would be a driver
• Essentially, demand
response on steroids
with autonomous controls
• DOE supporting the
vision with demonstration
projects and research
DOE presentation on smart buildings, Nov. 2017 10
Convert your infrastructure into flexible energy assets and get paid for it.
Refrigeration
Food Waste
Recycling
Supervisory and
Building
Management
Enterprise
Monitoring
Cold Rooms
Lighting
Bakery
Evaporator
Controllers
HVAC
Cargo Monitoring
Ecosystem Management and Energy Costs
11
The user experience is now tailored to specific personas/tasks.
Enterprise-level Software Upgrade OpportunityVisualizations Are Solution-specific
• Provide only required information
– Apply comprehensive filtering criteria• Time, data type, asset type, location, limits, etc.
• Provide highly graphical, intuitive views
– Expand adoption to include non-domain experts
• Complete specific use-cases
– Color-coded map view of sites with two-click navigation to ID root cause• Include prescriptive corrective action(s)
12
Traditional
Centralized DX Rack
Why Upgrade Your Existing Supermarket Refrigeration Infrastructure?
Refrigeration52%
Lighting16%
HVAC19%
Other13%
Annual SupermarketElectricity Consumption
Supermarkets use
three times more energy
per square foot than other
retail facilities.
Typical Centralized DX
Sources: ENERGY STAR, AICA ENERGY
• Most common architecture
• Inflexible asset
• Many refrigerant options:– R-22, R-404A, R-407A/F (high-GWP)
• Thousands of feet of pipe
• 3,000+ pounds per system
• Highest average leak rates:
25% avg. (targeted by global
refrig. reg.)
• Highest CO2e or LCCP footprint
• Familiar, viewed as simple
Peculiarities
71% REF and HVAC
$7.7B in electricity per year
14
Traditional Supermarket System
Parasitic Losses
• Flash gas in liquid lines
• Insulation damage or cracking off
• Condensing pressure swings
• Excessive suction line superheat
• Excessive compressor cycling
• Improper TXV SH adjustment
• Hunting EPRs
• Small leaks
• Excessive defrost times
• Longer pull-down after defrost
15
Typical Aging Supermarket Racks
• Three old racks, more than 1,000,000 BTU
• 15 RTUs
• Five cond. units
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The Journey to Energy Excellence — Effective vs. Efficient
En
erg
y E
ffic
ien
cy
Ongoing Performance Monitoring
Building/System
Project Concept
Design InstallationAdjustment Maintenance
Effective but NOT Efficient
Recommissioning/Optimization
Capital Upgrade
Latest Technology Efficiency
Deviation From OptimumLost E
ffic
iency
Time
Today
Maintain Optimum Efficiency and Effectiveness
17
Supermarket Optimization — Case Study
18
Overview:
• 20-year-old, 45,000 sq. ft. grocery located in
southwestern Ontario
• Medium- and low-temperature centralized rack system
• System (total 164 hp) operates with 10 semi-hermetic
Copeland™ compressors
Objective:
• Analyze the energy impact of the medium- and low-
temperature racks of retrofitting one compressor on
each to a Digital Discus™ compressor
18
Step 1
Establish Baseline Energy
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU
Upgrade
• Demand
Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital
• VFD
• Floating
Head/Suction
• Condensers
VFD
• Click and
Collect
20
Power Monitoring – Basic Need
Emerson
Emerson
21
Traditional Supermarket System
Good Poor
System Efficiency
22
Analysis Tools — Weather-Normalized Power Profile
Must measure baseline to understand effectiveness of upgrades and obtain utility incentives
Pre-optimization Energy Profile
Post-optimization Energy Profile
7°F 12°F 18°F 23°F 28°F 34°F 39°F 45°F 50°F 55°F 61°F 66°F 72°F 77°F 82°F 88°F
23
Step 2
Retro Commission Setpoints
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU
Upgrade
• Demand
Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital
• VFD
• Floating
Head/Suction
• Condensers
VFD
• Click and
Collect
25
Supermarket OptimizationSetpoint Adjustment, Retro Commissioning – Case Study
Step B Step C Step DStep A
• 20-year-old,Toronto-area store identified
• 1,000,000 BTU capacity (163 HP: MT and LT racks)
• 900,000 kWh total
• 5 medium-temp Discus
• 5 low-temp Discus
• Install energy monitoring equipment to baseline the store energy
• Climacheck equipment being used
• Measure weather-normalized energy
• Adjust setpoints, superheat, high/low press. settings, comp. cut in/out, SH, etc.
• Spent $3,500 on boards and relays to change from two fans cycling at a time to individual fan cycling to 70 °F min. SCT
• Use energy-monitoring equipment and assure “continuous commissioning”
• As soon as readings vary away from energy setpoint, investigate the cause of the variance, re-adjust to original setpoints to maintain optimal energy
Results: 18% savings were maintained for 8-month period before new upgrades were performed.
18% = 162,000 kWh savings26
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU Upgrade
• Demand Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital
• VFD
• Floating
Head/Suction
• Condensers VFD
• Click and Collect
27
Held the Savings8 Months
Saving 18%(162,000 kWh)
$0.14/kWh
$22,680
Step 3
Refrigeration Technology Upgrades Like Digital
What Is Digital?
• Copeland digital technology is fundamentally different from inverter-based modulation.
• The capacity modulation of the digital compressor is achieved by averaging the time between a “loaded state” and “unloaded state”.
• It is unique, reliable and very simple to apply.
Can also add a VFD to Discus (25–60 Hz range) AE21-1369 R4 29
Digital DiscusDigital Scroll™
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50% Output 70% Output
Why Include Digital in Your Refrigeration Retrofit and Remodel Projects?
• Reduces compressor cycling
• Increases contactor life/system reliability
• Improves system load match capability
• Improves suction setpoint range
• Improves energy efficiency
• In some cases, suction setpoints are lowered to compensate for swings in suction pressure due to compressor cycling. By increasing the suction setpoint, an energy savings can be achieved.
• For every 1 PSI increase in suction pressure, compressor power is reduced by approximately 2 percent.
• Up to 30 percent more efficient than using hot-gas bypass
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Supermarket Applications — Digital Upgrade MT Rack
Significant and immediate
reduction in compressor cycling
Digital Discus activated
72 psi 8 PSI
increase
Digital retrofit
89% reduction
in suction
pressure range
2D
3D
6D From 900 starts per day
to 12 starts in four days0
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Step 3
Digital Upgrade –Results From Case Study
Supermarket Optimization Digital Discus Upgrade
Step F Step G Step HStep E
• Digital upgrade to MT and LT rack
• Establish worst-performing MT and LT compressor
• Ones with the highest discharge temps were identified as the worst
• New Digital Discus were used instead of adding a digital retrofit kit due to high discharge temp. issue
• Ran the new MT Discus Digital and new LT Discus Digital at full load for one month to record the actual energy advantage of two new “fixed” capacity Discus vs. two that were running with elevated discharge temperatures
• 4% savings
• Enabled Digital Discus for MT and LT rack using the E2 enhanced suction group
– Medium-temp. saving with Digital = 75,000 kWh
– Low-temp saving with Digital = 47,000 kWh
• 12% additional savings
• Further testing was never completed
• Plans were to:
– Change new condenser, M&V for energy baseline
– Upgrade to ECM motors on cond. and compare to baseline
– Was also planning to add EEV and case controls and compare to baseline TXV
Total Digital Discus upgrade saving was 16% or
122,000 kWh, $0.14/kWh = $17,080 saving
33
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU Upgrade
• Demand
Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital or VFD
Compression
• Floating
Head/Suction
• Condensers
VFD
• Click and
Collect
34
Saving 18%(162,000 kWh)
$0.14/kWh
$22,680
Saving 16%
122,000 kWh
$0.14/kWh
$17,080
Digital Discus Compressor Upgrade Measurement and Verification
00
30.6 psig
31.4 psig
Pre Post
35
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
36
58 psig
68 psig
Pre Post
36
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
37
Third-Party Energy Reporting
38
Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)
Step 3
Other Refrigeration
Additions or Upgrades
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU Upgrade
• Demand
Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital or VFD
Compression
• Floating
Head/Suction
• Condensers
VFD
• Click and
Collect
Saving 18%(162,000 kWh)
$0.14/kWh
$22,680
40
Click-and-Collect Market Needs
Online Grocery Trend
41
42
Separate MT and LT Condensing Units Required
High Volume = Excessive Door Openings
Excessive Moisture – Potential Employee Safety Issue
Increase Consumer Demand Will Necessitate the Need for Walk-in
50% of consumers will not repeat business after a negative experience.42
“Lesson Learned” for C&C Volume
Differentiator
Complete Solution
++
Advanced
Condensing
Unit Controls
Remote Monitoring and Predictive Controls
Emerson Will
Work With Your
Preferred W/I Box
Supplier to
Deliver
the Solution.
43
Step 4
Medium-Temp.
Case Upgrades
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU Upgrade
• Demand
Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital or VFD
Compression
• Floating
Head/Suction
• Condensers
VFD
• Click and
Collect
45
Saving 18%(162,000 kWh)
$0.14/kWh
$22,680
Open
Closed
End User Benefits
• More than 60% reduction in energy (verified with M&V)
• Utilities rebate
• Tight temperature control
• Improved product quality
• Increased shelf life
• Warmer aisles, increased dwell times in aisles
Contractor Benefit
• Working on securing an additional 160 stores
Customer Pain
• High energy bills on 36’ of dairy case
• Large temperature swings in cases
• Latent pain, product quality and shelf life
Execution
• Added doors to 36’ of dairy cases
• Replaced 10 HP compressor with 5 HP Copeland
Digital Scroll
• Added XC634 Digital Scroll controller
Converting “Open” to “Closed” Cases in a Drugstore
46
Cold Thermal Energy Storage (CTES) — “kW” Saving
Axiom Exergy Viking Cold Rebound Technologies
47
Step 5
RTU Upgrades and
Demand Ventilation
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU Upgrade
• Demand
Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital or VFD
Compression
• Floating
Head/Suction
• Condensers
VFD
• Click and
Collect
49
Saving 18%(162,000 kWh)
$0.14/kWh
$22,680
50
Commercial HVAC Solutions Focused the Underserved Units
North American commercial building energy savings potential is sizable. There are ~7.3 M > five-ton rooftop units in North America.
North America Rooftop
Units — Installed Base
Commercial Buildings With HVAC69%
Rooftop Penetration in Commercial Buildings58%
Addressable Market
Food-Related
Non-Food Related
23%
1,029k
77%
3,991k
Transformative Wave
Solution for Rooftop Units
• VFD Control
• Advanced
Economizer Control
• Cloud-enabled
• Fault Detection
and Diagnostics
Rooftop Units~2.9M
Rooftop Units~6.6M
Five-ton Rooftop~2.4M
Five-ton Rooftop~4.9M
AC Units~3.2M
AC Units~11.0M
25–50%
Energy
Savings
RTU Fault Detection and Monitoring
Rooftop Upgrade Kit
50
Step 6
Condition-Based
Energy Maintenance
Energy Retrofit Opportunities
Journey to Energy Excellence
En
erg
y C
on
su
mp
tio
n (
Eff
icie
ncy)
Time
Current
State
Step 1
Baseline Energy
Audit
• Refrigeration
Setpoints
• Break/Fix Items
Step 2
Recommission to
Factory Specs
Future
State
Step 3
Refrigeration
Technology Upgrades
Step 4
Lighting and Other
Renewables Upgrades
Step 5
HVAC Technology
Upgrades
Step 6
Condition-based
Maintenance
6Energy Savings
• RTU Upgrade
• Demand
Control
Ventilation
• Adding Doors
• EEV, Cases
• ECM in Evaps
• CTES
• Digital or VFD
Compression
• Floating
Head/Suction
• Condensers
VFD
• Click and
Collect
52
Saving 18%(162,000 kWh)
$0.14/kWh
$22,680
Condition-based Maintenance
Regulations
Why Upgrade Your Existing Supermarket Refrigeration Infrastructure?
Refrigeration
Food Waste
Recycling
Supervisory
and Building
ManagementEnterprise
Monitoring
Cold Rooms
Cargo
Monitoring
Bakery
Evaporator
Controllers
HVAC
Leverage IoT
Power Management
1
2
3
Long-range Sustainability4
53
• Opportunities for energy efficiency are real, therefore savings available
• While each store is complex and unique, real-time, data-driven energy program allows for savings to be realized and proven
• Transforming energy-intensive supermarkets into a flexible asset is within your reach
Conclusion
54
Questions?
DISCLAIMER
Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or
implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for
use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such
use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated
herein or that other measures may not be required.
Thank You!
55
For further supermarket information, visit: Climate.Emerson.com/E360Webinar32