How to Meet 2017/2020 Energy Regulations U.S. Commercial Foodservice Ani Jayanth Foodservice Marketing Manager Emerson Brian Buynacek Senior Refrigeration Engineer and Marketing Consultant Emerson
How to Meet 2017/2020 Energy Regulations
U.S. Commercial Foodservice
Ani JayanthFoodservice Marketing ManagerEmerson
Brian BuynacekSenior Refrigeration Engineer and Marketing ConsultantEmerson
This presentation is intended to highlight changing developments in the law and industry topics. The law is frequently evolving and information and publications in this presentation may not reflect the latest changes in the law or legal interpretations. The statements and information provided in this presentation should not be construed as legal advice or legal opinion regarding any specific facts or circumstances, but is intended for general informational purposes only. The views and statements expressed during this presentation are the personal opinions of the presenter and do not those of Emerson Climate Technologies, Inc. or its affiliated companies. You should consult an attorney about your situation and specific facts and you should not act on any of the information in this presentation as the information may not be applicable to your situation. Although all statements and information contained herein are believed to be accurate and reliable, they are presented without warranty of any kind. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments. 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. This presentation may not be copied or redistributed without the express written consent of Emerson Climate Technologies, Inc.
Disclaimer
DOE Equipment Regulations Survey
3
Source: Department of Energy
• Effective January 2020 on new equipment
• WICF measured in three major components
• AWEF measured using AHRI-1250 testing standard–Each equipment class assigned
equation–Variable: Q = system capacity
• Effective March 2017 on new equipment
• CRE measured in kWh/24-hour day–Each equipment class assigned
equation–Variable: Total Display Area (TDA)
or volume
Industry Reach-In Solid Door Refrigerator Energy Draw
• Effective January 2018 on new equipment
• ACIM measured in kWh/100 lbs ice– Each equipment class assigned
equation– Variable: H = harvest rate in
pounds per 24 hours
Commercial refrigeration equipment
Walk-in coolers and freezers (WICF)
Automatic commercialice makers
From 20% to 50% energy reduction required for systems, depending on class 5% to 25% energy reduction required
EPA’s Final Rule, July 20, 2015, and September 26, 2016Changed listing status of certain HFCs*
*Abbreviated – For complete listing, see EPA Final Rule; go to: https://www.gpo.gov/fdsys/pkg/FR-2015-07-20/pdf/2015-17066.pdfSee proposed rule; go to: https://www.gpo.gov/fdsys/pkg/FR-2016-04-18/pdf/2016-08163.pdf
Final Rule: July 20, 2015 Final Rule: September 26, 2016
Phase-outrefrigerant
Super-market(New**)
Super-market
(Retrofit***)
Remote condensing unit(New)
Remote condensing unit
(Retrofit***)
Stand-Alone Refrigerated food
processing and dispensingequipment
(New)
Cold storage
warehouses (New)
Ice machines
(New)
Verylow-temp
refrigeration(New)
MT < 2,200 BTU/hr. and not contain flooded
evap. (New)
MT ≥ 2,200 BTU/hr. with or without flooded
evap. (New)
LT(New)
LT and MT
(Retrofit***)
R-404A/507A Jan. 1, 2017 July 20, 2016 Jan. 1,
2018July 20,
2016 Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 July 20,2016 Jan. 1, 2021 ^Jan. 1, 2023 OK OK
R-410A OK - OK - Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 - Jan. 1, 2021 ^Jan. 1, 2023 OK OK
R-407A/C/F OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 OK ^Jan. 1, 2021R-407C/F OK
R-407A:^Jan. 1, 2023
OK R-407C only
HFC-134a OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 OK OK OK OK OK -Likely alternatives(Emerson perspective)
R-448A/449A OK OK OK OK
Neither SNAP-approved, nor
banned
Neither SNAP-approved, nor
bannedOK OK for
LT only - - OK -
R-450A/513A OK OK OK OK OK OK OK OK OK OK OK -
R-290 - - - - OK OK OK - - - OK OK
R-744 OK - OK - OK OK OK - OK OK - OK
R-717OK
(in primary loop of secondary
system)
-
OK (In primary
loop of secondary system)
-OK
(in primary loop ofsecondary system)
OK (in primary loop ofsecondary system)
OK (in primary
loop ofsecondary system)
OK (in primary
loop ofsecondary system)
OK (in primary loop ofsecondary system)
OK OK -
** Includes ice machines connected to a supermarket rack refrigeration system.*** EPA uses term “retrofit” to indicate the use of a refrigerant in an appliance that was designed for and originally operated using a different refrigerant.
Term does not apply to upgrades to existing equipment where the refrigerant is not changed.
4
12
Compliance Will Not Be Easy
Opportunity to Comply With One Design Cycle Change
EPA Refrig.
DOE Energy
2017 2018 2019 2020 2021Supermarket (Rack)
Walk-In (Remote CDU)CoolerFreezer
Reach-In (Stand-Alone)Cooler <2,200 BTU
>2,200 BTUFreezer
Ice Machine
Dispensing
<2,500 GWP
<2,500 GWP
20–40%
<600 GWP
<600 GWP<1,500 GWP
30–50%
5–15%
1/1/17
1/1/18
3/27/17
1/1/18R-290 Approved
1/1/20
1/1/19
1/1/20
20–30%
Awaiting FinalASRAC
<1,500 GWP
EnergyEnvironment
EconomicsEquipment
5
Yes52%
Not yet44%
OEM Preparedness to Meet Compliance Dates
Level of Preparedness: Level of Preparedness:
Equipment Passes DOE Regulations:Equipment Passes EPA Regulations:
EPA Plan in Place DOE Plan in Place
Very prepared Somewhat prepared Only slightly prepared Not at all prepared
(mean)48%
(mean)74%
Yes57%
Not yet36%
Over Half Have a Plan in Place and Are Prepared to Meet Compliance Dates. This Leaves Quite a Few Companies Not Ready for the Change.
6
13% 52% 15% 17% 15% 45% 19% 17%
OEM-Specific Preparations for Meeting DOE Regulations
We’re lab testing as a way to prepare.
We’re seeking guidance on how to be better prepared.
We have a product road map.
We’re communicating our plans to customers.
Other
62%
49%
43%
32%
13%
End use customers
Aftermarket/wholesalers/distributors
Contractors
Other
87%
47%
20%
13%DOE preparations
Communicating plan to … (among those communicating plans to customers)
Seeking guidance from … (among those seeking guidance to prepare)
Component manufacturers
Consultants
End use customers
Other
87%
35%
22%
9%
While 62% Are Lab Testing to Prepare for DOE Regulations, the Remaining Two in Five Are Not.Many customers are still seeking guidance on becoming better prepared.
7
Agreement With Statements Related to Regulatory Changes
Top-2 Box
I expect some componentswill change.
I expect some of our productsto become obsolete.
I expect component costs to increase.
89%
63%
73%
5 = Completely Agree 4 3 2 1 = Completely
Disagree
77%
53%
51%
12%
10%
22%
10%
14%
20%
2%
10%
4%
14%
4%
The Majority Expect Components Will Change Based on the Regulations. This, in Turn, Will Impact Cost Negatively.
Top-2 Box
8
Source: Department of Energy
Commercial Refrigeration Equipment Equipment Classes
Low- or Medium-Temperature
Vertical, Semi-Vertical, Horizontal or Service
Over Counter
Self-Contained or Remote Condensing
With or Without Solid/Transparent Doors
Commercial Refrigerator and Freezer
Equ
ipm
ent A
ffect
ed
33+ Classes of Equipment20+ Sizes/Eqp. Class
Buffet Tables, Salad Bars, Prep Tables Not Affected Depending Upon Refrigeration Construction
9
Buffet Tables, Salad Bars, Prep Tables BeyondScope of Energy Mandates
Source: Department of Energy
10
RegulatedTop Rail
BottomStorage
Regulated Not RegulatedNot RegulatedAirflow Airflow
CRE Prep and Buffet Tables Architectures and Compliance Note
Source: Department of Energy
Top Rail Bottom Storage Certification Required Criteria
Power Supply No Power Supplied or From Common Supply With Top
See Refrigeration Requirements Single Energy Source
Power Supply Power Supply Yes Dual Energy Source With Single Source Requirement
Top Rail Bottom Storage Certification Required Criteria
Refrigerated: Cold Wall or Forced Air
Dry –Non-Refrigerated No Regular Buffet/Prep Construction –
No Classification
Refrigerated: Cold Wall or Forced Air With Heat Being Rejected Directly
Into Lower Section
Refrigerated: Air In Lower Section Coming
in Direct ContactWith Top Rail and Single Condensing
Unit
No
Heat From Upper Rail Is Being Absorbed Directly Into Lower Section Refrigeration System With Single Energy Source and
Single Refrigeration System
Refrigerated: Cold Wall or Forced Air With No Direct
Contact With Lower Section
Refrigerated: Cold Wall or Forced Air With No Direct
Contact With Rail Section and Single Condensing Unit
Yes
Heat From Upper Rail Is Not Being Absorbed Directly Into Lower Section
Refrigeration System With Single Energy Source and Single Refrigeration System
Refrigerated: Cold Wall or Forced Air
With Its Own Condensing Unit
Refrigerated: Cold Wall or Forced Air
With Its Own Condensing Unit
YesDual Refrigeration System With Single
Refrigeration System Requirement, Single or Dual Energy Source
Can
Be
Test
ed
w/D
OE
Te
st P
roce
dure
Can
’t Be
Tes
ted
w/D
OE
Test
Pro
cedu
re
There Are No Exemptions From the Energy Standard for Commercial Refrigeration Equipment. However, There Are Some EquipmentTypes That Do Not Have a Test Procedure and Therefore Do Not Have to be Certified at This Time.
11
CRE Equipment DOE Analysis and Equations
Source: Department of Energy
• X-axis: size of equipment ft3• Y-axis: energy draw kWh/day• Equation format: Y = m(x) + b• kWh = m(ft3) + b
• 33 classes of equipment• Remote condensing and self-contained open
cases will not require major efficiency improvement challenges
• Self-contained vertical reach-ins will require significant efficiency improvement changes
2010 2012 2017 2010 2012 2017 % Delta 2010 2012 2017 % DeltaVOP.RC.M 0.82 x TDA + 4.07 0.64 x TDA + 4.07 4.07 4.07 0% 0.82 0.64 -22%VOP.RC.L 2.27 x TDA + 6.85 2.2 x TDA + 6.85 6.85 6.85 0% 2.27 2.2 -3%SVO.RC.M 0.83 x TDA + 3.18 0.66 x TDA + 3.18 3.18 3.18 0% 0.83 0.66 -20%SVO.RC.L 2.27 x TDA + 6.85 2.2 x TDA + 6.85 6.85 6.85 0% 2.27 2.2 -3%HZO.RC.M 0.35 x TDA + 2.88 0.35 x TDA + 2.88 2.88 2.88 0% 0.35 0.35 0%HZO.RC.L 0.57 x TDA + 6.88 0.55 x TDA + 6.88 6.88 6.88 0% 0.57 0.55 -4%VCT.RC.M 0.22 x TDA + 1.95 0.15 x TDA + 1.95 1.95 1.95 0% 0.22 0.15 -32%VCT.RC.L 0.56 x TDA + 2.61 0.49 x TDA + 2.61 2.61 2.61 0% 0.56 0.49 -13%HCT.RC.M 0.16 x TDA + 0.13 0.16 x TDA + 0.13 0.13 0.13 0% 0.16 0.16 0%HCT.RC.L 0.34 x TDA + 0.26 0.34 x TDA + 0.26 0.26 0.26 0% 0.34 0.34 0%VCS.RC.M 0.11 x V + 0.26 0.1 x V + 0.26 0.26 0.26 0% 0.11 0.1 -9%VCS.RC.L 0.23 x V + 0.54 0.21 x V + 0.54 0.54 0.54 0% 0.23 0.21 -9%HCS.RC.M 0.11 x V + 0.26 0.1 x V + 0.26 0.26 0.26 0% 0.11 0.1 -9%HCS.RC.L 0.23 x V + 0.54 0.21 x V + 0.54 0.54 0.54 0% 0.23 0.21 -9%SOC.RC.M 0.51 x TDA + 0.11 0.44 x TDA + 0.11 0.11 0.11 0% 0.51 0.44 -14%SOC.RC.L 1.08 x TDA + 0.22 0.93 x TDA + 0.22 0.22 0.22 0% 1.08 0.93 -14%VOP.SC.M 1.74 x TDA + 4.71 1.69 x TDA + 4.71 4.71 4.71 0% 1.74 1.69 -3%VOP.SC.L 4.37 x TDA + 11.82 4.25 x TDA + 11.82 1.82 1.82 0% 4.37 4.25 -3%SVO.SC.M 1.73 x TDA + 4.59 1.7 x TDA + 4.59 4.59 4.59 0% 1.73 1.7 -2%SVO.SC.L 4.34 x TDA + 11.51 4.26 x TDA + 11.51 1.51 1.51 0% 4.34 4.26 -2%HZO.SC.M 0.77 x TDA + 5.55 0.72 x TDA + 5.55 5.55 5.55 0% 0.77 0.72 -6%HZO.SC.L 1.92 x TDA + 7.08 1.9 x TDA + 7.08 7.08 7.08 0% 1.92 1.9 -1%VCT.SC.M 0.12 V + 3.34 0.1 x V + 0.86 3.34 0.86 -74% 0.12 0.1 -17%VCT.SC.L 0.75 V + 4.10 0.29 x V + 2.95 4.1 2.95 -28% 0.75 0.29 -61%VCS.SC.M 0.10 V + 2.04 0.05 x V + 1.36 2.04 1.36 -33% 0.10 0.05 -50%VCS.SC.L 0.40 V + 1.38 0.22 x V + 1.38 1.38 1.38 0% 0.40 0.22 -45%
Equations y-Intercept Slope
12
CRE Equipment DOE Analysis and Equations
13
Source: Department of Energy
Comparing 2017 vs. 20101. Improvement reduces relatively for larger size machines
• VCT.SC.M2. Improvement increases substantially for larger size machines
• VCT.SC.L• VCS.SC.L
3. Improvement levels out for larger machines• VCT.SC.L• VCS.SC.L• VCS.SC.M
VCT.SC.M
VCT.SC.L
VCS.SC.M
VCS.SC.L
25%
28%
31%
34%
37%
40%
43%
46%
49%
52%
55%
58%
61%
64%
67%
70%
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
2017
v. 2
010
Ener
gy R
educ
tion
Diff
eren
ce %
Size ft3
Source: Department of Energy
VCT.SC.M VCT.SC.L VCS.SC.M VCS.SC.L
2010 kWh = 0.12(V) + 3.34
0.75(V) + 4.10
0.10(V) + 2.04
0.40(V) + 1.38
2017 kWh = 0.10(V) + 0.86
0.29(V) + 2.95
0.05(V) + 1.36
0.22(V) + 1.38
Y-intercept % change -74% -28% -33% 0%
Slope % change -17% -61% -50% -45%
Walk-in Coolers and Freezers (WICF)Equipment Classes
Medium- or Low-Temp
Multiplex Condensing
Recip. Hermetic, Semi-Hermetic Recip. or Scroll Compression
<9K BTU/h or >= 9K BTU/h
Indoor or Outdoor
Medium- or Low-Temp
Dedicated Condensing
• Dedicated– Single walk-in feed
– A packaged dedicated system where the unit cooler and condensing unit are integrated into a single piece of equipment
– A split dedicated system with separate unit cooler and condensing unit sections
• Multiplex– Unit coolers matched to
multiplex condensing rack system
14
Source: Department of Energy
WICF AWEF Improvement Design Option CostsDedicated Condensing MT/LT by BTU/h
6000 9000 54000 72000 18000 54000 6000L M
DCI - HER $1,528 $1,648 $2,130 $1,448I - SCR $1,754 $1,873 $6,754 $2,348 $3,575 $6,233I - SEM $1,993 $4,653 $2,588 $4,103 $4,242O - HER $1,558 $1,678 $2,160 $1,479O - SCR $1,785 $1,903 $6,819 $2,379 $3,615 $6,289O - SEM $2,024 $2,154 $7,246 $9,133 $2,618 $4,143 $4,286
$0
$2,000
$4,000
$6,000
$8,000
$10,000
$12,000
$14,000
$16,000
Average Costs
9000 6000 54000 72000 18000 54000 6000L M
DCI - HER $2,171 $2,370I - SCR $2,365 $2,204 $7,568I - SEM $2,452 $7,571 $4,387 $4,568O - HER $2,494O - SCR $9,668 $2,682 $3,978 $7,003O - SEM $10,530 $13,706 $4,603 $4,771
$0
$2,000
$4,000
$6,000
$8,000
$10,000
$12,000
$14,000
$16,000
New Costs for Meeting AWEF
Source: Department of Energy
$3,269 $4,684 +43%
15
Automatic Commercial Ice MakersOverview
16
Source: Department of Energy
• Affecting batch ice machines also known as “cubers”• Affecting continuous ice machines also known as “flakers” or “nuggets”
Air or water cooled
Self-contained or remote
condensingVarious harvest
rates
• Frozen carbonated beverage machines not affected
Polling Question 1
What is this audience’s level of understanding, channel constituent collaboration and preparedness to address these regulatory challenges?
A. Didn’t even know about thisB. Haven’t started engaging the channel on getting preparedC. Getting prepared to engage the channel nowD. I’m ready and have communicated to all stakeholders in my channel
17
Commercial Refrigeration EquipmentDesign option vs. cost
18Source: Department of Energy
$0
$10
$20
$30
$40
$50
$60
$70
$80
$90
0% 5% 10% 15% 20% 25%
Higher Eff Compr
Hot-Gas Antisweat
ECM Cond Fan 0.5 year
1.0 year
2.0 yearsBPM Compr Mtr
VS Compr
Better Insulation
Payback
$ OEM Cost Adder
% Energy Saving
Solid-Door Reach-In Refrigerator(DOE/ADL Study)
ECM Evap Fan
kWh/Day
kWh/day = comp. energy draw + lighting + fan + controls + others
Total System Measurement Based on Equipment Type; CDU Is Treated as Component
Better insulation BPM motor
vs. comp.
System Compressor CDU component
ECM evaporator / condenser fan
High-effy. comp.
Hot gas anti-sweat
LED lighting
Reach-ins: Energy Considerations
19
• DOE 2017 compliance very challenging, especially self-contained with doors– ENERGY STAR promotes even higher
efficiency levels
• Design challenge compounded with high-GWP HFC phase-down by 2020
• Requires evaluation of multiple options:– Compressor– Condensing unit– Fan motors– Control– Future refrigerant planning
Walk-in Coolers and Freezers (WICF)Annual Walk-in Energy Factor (AWEF)
• AWEF values calculated using AHR-1250 calculator with plugged-in assumptions for factors
• Can be simulated in the absence of full system build
Source: Department of Energy
20
DOE Design Options to Meet AWEF Summary
Floating Head Pressure
Modulating Evaporator Fans
Electronically Commutated
Motors
Improved Evaporator Fan
Blades
Improved Condenser Fan
BladesImproved CoilHot Gas Defrost
Temperature-initiated,
Temperature-terminated Defrost
Variable Speed Compressor
Variable Speed Condenser Fans
Variable Speed Evaporator Fans
Ambient Sub-cooling
Source: Department of Energy
21
Floating Head Pressure vs. Fixed
22
Source: Emerson
Taking Advantage of Low Ambient
23
Source: Emerson
Automatic Commercial Ice MakersCycle Understanding
Start• 30/110• 15% Run Time
Stabilize• 15/115• 70%
Finish• 0/105• 10%
Harvest• 45/95• 5%
Ice
Mac
hine
Tra
nsie
nt M
odel
Ice Machine Improvement Levers
Continuous BothBatch
24
Total Walk-ins Reach-ins
Ice/FCB/SS
Racks
75% 74% 64% 83%
75% 74% 55% 75%
56% 71% 46% 75%
69% 60% 55% 67%
44% 37% 27% 50%
50% 17% 18% 50%
38% 37% 18% 25%
50% 20% 9% 17%
56% 20% 0% 50%
44% 14% 9% 33%
Measures Being Taken to Increase Energy Efficiency
71%
69%
65%
59%
35%
31%
29%
26%
26%
18%
Switching to more efficient fanmotors
Switching to more efficientcompressors
Using LED lighting
Using more electronic controls
Using larger heat exchangers
Switching to electronicexpansion valves
Improving the amount ofinsulation
Switching to scroll compressors
Using adaptive electric defrost
Using floating head pressures
More Efficient Fan Motors and Compressors, Along With LED Lighting and Electronic Controls, Are Being Used to Increase Energy Efficiency and Provide the Best ROI.
Top energy efficiency
improvements that will
provide the best return on
investment
25
37,616CRE
797ACIM
1,673WICF
• Google “DOE CCMS” or …– https://www.regulations.doe.gov/ccms
• DOE enforcement mechanism– Fines have been imposed
• Annual certification required by submitting new CCMS and supplemental testing forms each year
Current Number of Models Listed
Source: Department of Energy
26
Polling Question 2In what way would you describe these regulatory challenges?
A. Negative: It’s going to hurt my business.B. Positive: It’s going to be an opportunity for me to differentiate and lead.
27
Questions?
DISCLAIMERAlthough 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!