The Magazine for ENERGY EFFICIENCY and WATER CONSERVATION in Industrial Cooling Systems March 2017 5 CHILLER & COOLING TOWER TECH PICKS H 2 O kW CO 2 INDUSTRIAL COOLING SYSTEMS 12 Ball Corporation Engineers a Reduction in Cooling Tower Load 16 Designing a Dedicated Modern Wine Cooling System COOLING TOWERS & CHILLERS 19 Cooling Towers Offer Data Centers Water and Energy Savings 24 2017 AHR Show Report
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The Magazine for ENERGY EFFICIENCY and WATER CONSERVATION in Industrial Cooling Systems
Mar
ch 2
017
5 CHILL
ER &
COOLIN
G TOWER
TECH
PICK
S
H 2O
kW
CO2
INDUSTRIAL COOLING SYSTEMS
12 Ball Corporation Engineers a Reduction in Cooling Tower Load
16 Designing a Dedicated Modern Wine Cooling System
COOLING TOWERS & CHILLERS
19 Cooling Towers Offer Data Centers Water and Energy Savings
March 22-23, 2017Pennsylvania Convention Center, Philadelphia, PA
www.globalconevent.com
Energy, Power & Facility ManagementStrategies & Technologies ExpoImprove your energy management program, and get up to speed on the current generation of innovative technologies.
Presented By
www.energyevent.com www.energycongress.com
ATTENDANCE | 770.447.5083 x226
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CONFERENCE - SEMINARS - TRADE SHOW
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COOLING TOWERS & CHILLERS
COLUMNS
12 THE COOLING SYSTEM ASSESSMENT Ball Corporation Engineers a Reduction in Cooling Tower Load By Chiller & Cooling Best Practices Magazine
16 Designing a Dedicated Modern Wine Cooling System By Kevin Trowhill, Century Refrigeration
19 Cooling Towers Offer Data Centers Water and Energy Savings By Douglas Bougher and Kent Martens, P.E., SPX Cooling Technologies
24 SHOW REPORT Chillers and Cooling Towers at 2017 AHR EXPO By Rod Smith, Chiller & Cooling Best Practices Magazine
4 From the Editor
5 Resources for Energy Engineers Chiller & Cooling Tower Technology Picks
29 Industrial Cooling System Industry News
33 Advertiser Index
INDUSTRIAL COOLING SYSTEMS
12
19
24
3 coolingbestpractices.com
COLUMNS M A R C H 2 0 1 7 | V O L U M E 3 , N O . 1 |
“The fans are running at a lower speed, and the makeup water volume
is down,” Nelson told us. “More importantly, in the summer time when
there’s the max load on the cooling tower, we’re not at the max capacity
on the tower, so our office heat pumps aren’t kicking out.”
The heat recovery project has also yielded other benefits. The heat
generated inside the heat exchanger is used to pre-heat the incoming
water to certain production applications requiring heated water. This
has reduced the natural gas consumption of the boilers.
Cleverly Engineered Energy-Saving Installations
The engineers at Ball Corporation achieved energy savings with a heat
exchanger, lowering demand on a hot water heaters and the cooling
tower simultaneously. The cleverly engineered system has also improved
the efficiency of the compressed air system, as it is now receiving cooler
chilled water.
“When I go through the math, it all kind of checks,” Nelson said. “There
are efficiency losses, but I can honestly say we’re taking significant BTUs
an hour out of the cooling tower, and significant BTUs out of our natural
gas demand for heat. All while improving the efficiency of our cooling
tower, so I didn’t have to spend money on buying a new one.”
With a heat exchanger procured from another facility, the only
additional costs included piping and freight costs. The engineers at
Ball expect to hit an excellent ROI target. Also important to note, the
ambient conditions of the office building next door are no longer
impacted by the dog days of summer.
To read more about Sustainability at Ball Corporation, visit www.ball.com/sustainability
SPONSORED BY:
Join Keynote Speaker, Tim Dugan, President and Principal Engineer of Compression Engineering Corporation to examine when it is appropriate to install a variable speed drive air compressor. Manufacturing scenarios and environments with differing demand profiles will be analyzed to determine the energy-savings potential of a VSD air compressor in a compressed air system.
Our first Sponsor Speaker is Steve Bruno, Product Marketing Manager for Atlas Copco. His presentation is titled, “Proper Sizing of VSD Compressors”. Techniques and knowledge will be shared on how to properly size a VSD air compressor to supply the fluctuating load. The presentation will also discuss how to monitor energy usage and specific power.
Our second Sponsor Speaker is Pascal van Putten, CEO of VPInstruments. His presentation is titled, “Air Flow Consumption Fingerprint.” The “consumption fingerprint” is a different approach to selecting the right air compressor configuration, based on flow measurements and statistical histogram data. He will show the value of histograms in optimization projects.
Receive 1.0 PDH Credit.
Register for Free Today at airbestpractices.com/magazine/webinars
March 30, 2017 – 2:00 PM EST
Proudly Presenting the 2017 Expert Webinar Series
Purging CompressedAir Demand-Side Demons at a PET Bottle-Blowing Plant
Register for Free Today atairbestpractices.com/magazine/webinars
March 31, 2016 2-3 pm EST
Mr. Rhoten served as the
President of Hope Air
Systems for 40 years and
remains active as a Senior
Project Engineer designing
compressed air systems for
the plastics industry.
Join Presenter Pete Rhoten as he describes a
PET blow-molding case study with lessons
applicable to all types of production equipment.
Demons, hiding inside production equipment,
often cause significantly disruptive and
expensive compressed air pressure drops and
leaks. In this case they were found in poorly
maintained bypass maintained bypass regulators and inlet filters. A
long-term, six-step action plan was created,
introducing compressed air flow measurement,
to lower over-all plant pressure requirements.
Proudly Presenting the 2016 Expert Webinar Series
Tim Dugan is the President of Compression Engineering Corporation.
Steve Bruno is a Product Marketing Manager for Atlas Copco.
Pascal van Putten is the CEO of VPInstruments
When to Install a VSD Air
Compressor
To read more about Heat Recovery Projects visit www.coolingbestpractices.com/system-assessments/heat-recovery
To read similar Cooling Tower Technology articles visit www.coolingbestpractices.com/technology/cooling-towers
Additional energy-saving factors to consider
Water-cooled technologies are more efficient,
particularly when “free cooling” is employed
during periods of cooler weather. Free
cooling, also referred to as “water-side
economizer” cooling, is an economic method
of using low external air temperatures to
assist in chilling water. When operating
in free cooling mode, the water from the
cooling tower is cold enough that mechanical
refrigeration by the chiller is not required.
This reduces the energy requirement
significantly, typically by 75 percent or more.
To take advantage of the energy savings
possible with free cooling, there must be
sufficient hours of cold weather to justify the
additional equipment investment for the plate/
frame heat exchanger and other components.
An evaluation of the benefits of cooling towers
in data center cooling must also consider
“variable flow,” another method to reduce
energy consumption. Cooling towers are sized
for summer design condition; variable flow
enables users to reduce the water flow from
the cooling tower to the chiller during cooler
seasons. Fans are operated at a lower speed,
which reduces energy usage. Taking advantage
of free cooling and variable flow modes can
dramatically reduce cooling tower energy use.
Cooling tower modularity provides another
advantage. Data center owners may prefer to
build out their facilities over time as server
demand grows. To control initial capital
expenditures and operating costs, data center
operators may add cooling capacity later as
needed by utilizing systems that incorporate
factory-assembled modular cooling towers
as the facility grows. It is important for data
center construction to be completed on
schedule so that servers can be operational
quickly to generate revenue. Modular pre-
assembled and field-erected cooling towers
can meet time-sensitive delivery requirements
and construction schedules.
Weighing the water options
There are many combinations of evaporative
and mechanical cooling solutions that can
be evaluated to meet data center cooling
requirements. As the discussion of water
is added to the list of design considerations,
it is important to understand and evaluate
the relationship between utility power and
local water consumption in order to make
well-reasoned decisions for achieving energy
and water conservation goals.
About the Authors
Douglas Bougher is commercial director for HVAC and Refrigeration markets and Kent Martens is western regional sales manager for SPX Cooling Technologies, Inc., Overland Park, KS. For more information visit www.spxcooling.com
1 Torcellini, P., Long, N. and Judkoff, R. “Consumptive Water Use for U.S. Power Production.” December 2003. Accessed October 31, 2016. http://www.nrel.gov/docs/fy04osti/33905.pdf
2 National Renewable Energy Laboratory. “National Solar Radiation Data Base. 1991-2005 Update: Typical Meteorological Year 3.” NREL.gov http://rredc.nrel.gov/solar/old_data/nsrdb/1991-2005/tmy3/
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2017 AHR EXPO Show Report CHILLER & COOLING TOWER TECHNOLOGY
By Rod Smith, Chiller & Cooling Best Practices Magazine
cpThe 2017 AHR EXPO was held January 30 to February 1 in Las Vegas. The 2017 AHR Expo set several records, including attendance of more than 68,000 registered visitors and exhibitor personnel. The Show was by far the largest and best attended Expo in the Western states, with some 1,968 exhibiting companies.
Cooling Towers
Evapco presented their Eco-ATW line of 10-400 ton (single cell)
closed circuit cooling systems featuring a broad array of water and
energy-saving features. I spoke with Assistant Product Manager (for
Closed Circuit Coolers) Matthew Shank who said, “The units feature
Baltimore Air Coil’s Jim Fino reviewed the HXV HYBRID line of cooling towers focused on maximizing energy and water conservation.
Matthew Shank next to the EVAPCO Eco-line of ATW closed circuit coolers.
pp Improving energy efficiency by 2.8 percent compared to 2014 and more than 20 percent since 2005. Since 2009, Colgate has avoided over $295 million in energy costs while reducing carbon dioxide emissions by more than nine percent.
pp Implementing a climate change strategy that influences the company’s carbon footprint through ambitious emissions goals, management of energy, and providing for low carbon products, energy, and supply chain. The company increased renewable energy purchases by 30 percent in the United States.
pp Engaging employees through Energy Treasure Hunts to identify over 200 energy reduction ideas for an estimated 36,664 megawatt hours in energy savings.
pp Achieving the ENERGY STAR Challenge for Industry at 13 facilities, 10 of which are repeat winners.
pp Expanding the “Save Water” campaign in new markets to raise awareness of water conservation.
pp Sharing best practices with other ENERGY STAR partner companies.
For more information, visit www.colgate.com or www.energystar.gov
To view the Colgate Sustainability Report visit: http://www.colgate.com/app/Colgate/US/Corp/LivingOurValues/Sustainability/HomePage.cvsp
Aggreko Acquires DRYCO, LLC.
Power generation and HVAC specialty rental company, Aggreko plc,
has acquired DRYCO, LLC of Chicago, Illinois for an undisclosed
amount. DRYCO was founded in 2000, and specializes in moisture
control, drying, heating, and cooling applications within the shipping,
manufacturing, food processing, construction, and industrial painting
industries.
It has 10 full-service locations in North America, and has built a strong
customer base in its targeted industries, which complement Aggreko’s
growth strategy. The acquisition will add more than 60 experienced
employees and approximately 6,000 specialized assets to Aggreko’s fleet.
“This acquisition of DRYCO combines the deep technical strength of
two highly respected market leaders and provides our customers with
an unparalleled range of services that address their HVAC and moisture
control needs,” said Mel Parker, Managing Director, Aggreko North
America. “We are pleased to have DRYCO join the Aggreko team, enabling
us to accelerate growth and meet the rapid demand for our services in
the shipping, food and beverage, and painting and coatings industries.”
Joe Schroeder, CEO of DRYCO, said, “DRYCO is excited to join
forces with Aggreko to become the leading provider of drying and
dehumidification services. Our teams share the same passion and
commitment to service excellence, and we look forward to working
together to further grow Aggreko’s business.”
Aggreko plans to fully integrate the operations of DRYCO into its North
America business and is developing expansion plans to enter additional
sectors and global markets.
For more information, visit www.aggreko.com.
ASHRAE/IES Publish 2016 Energy Efficiency Standard
Numerous energy savings measures resulting from industry input are
contained in the newly published energy efficiency standard from
ASHRAE and IES.
ANSI/ASHRAE/IES Standard 90.1-2016, Energy Efficiency Standard
for Buildings Except Low-Rise Residential Buildings, contains
125 addenda published since the 2013 standard. The 2013 standard
currently serves as the commercial building reference standard for state
building energy codes.
This 2016 version is the 10th edition published since the original
standard was first published in 1975 during the energy crisis of the
United States. “It is the overall goal of each version to create a consensus
standard that saves energy and is technically feasible and cost effective,”
said, Drake Erbe, chair of the Standard 90.1 committee. “In addition, DRYCO specializes in moisture control, drying, heating, and cooling applications.
as a result of a strategic initiative begun in the 2013 cycle, the 2016
version has a new format that we believe will be easier for users, a new
way of incorporation of reference material from other standards starting
with climate data, and a performance path for compliance that rewards
designs for achieving energy cost levels above the standard minimum.”
Formatting
The standard has made significant formatting changes to improve its
use. These include a one-column format for easier reading; exceptions
separated and indented, set apart with a smaller font size; all defined
terms are italicized; and alternating coloring scheme for table rows.
The most significant technical changes are as followed:
Building Envelope:
pp The mandatory provisions include the addition of envelope verification in support of reduced air infiltration and increased requirements for air leakage to overhead coiling doors.
pp The prescriptive requirements include increased stringency requirements for metal building roofs and walls, fenestration, and opaque doors. Requirements for Climate Zone 0 have been added.
pp Improved clarity of the standard ranged from defining exterior walls to building orientation to clarity around the effective R-value of air spaces
Lighting:
pp Modified control requirements that make the application of advanced lighting controls easier for increased energy savings
pp Modification of exterior and interior lighting power densities that reflect the efficiency gains from LED technology in specific applications where they are proven to be effective
pp Added minimum requirements for lighting in dwelling units to set limits on light source efficacy
pp Added additional control for lighting in parking areas based on occupancy to reduce energy use
Mechanical:
pp Chilled water plant metering – For the first time, the standard is requiring large electric driven chilled water plants to be monitored for electric energy use and efficiency.
pp DOAS requirements – Dedicated outdoor air systems were introduced over 25 years ago but there were no rating or efficiency requirements with which to comply. For the first
time, this product class does have both efficiency and rating requirements with which they have to comply.
pp Elevator efficiency –Introduces requirements for designs to include both usage category and efficiency class. While a minimum threshold is not listed, it is the first step toward including minimum elevator efficiency requirement in a future standard. The standard referenced is an ISO standard since this the current industry standard for efficiency.
pp Economizer diagnostics – The standard is implementing requirements that air cooled DX cooling unit with economizers have a monitoring system to determine that the air economizer is properly working.
Energy Cost Budget (ECB) and Modeling. A significant change
to the application of Appendix G as follows:
pp Appendix G now can be used as a path for compliance with the standard. Previously Appendix G was used only to rate “beyond code” performance of buildings. This new version of Appendix G
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can show compliance with the 2016 version of the standard in the following manner:
p` The proposed building design requires a new metric the Performance Cost Index (PCI) and demonstration that it is less than that shown in Table 4.2.1.1 based on building type and climate zone.
p` Another change is that the baseline design is now fixed at a certain level of performance, the stringency or baseline of which is expected not to change with subsequent versions of the standard. Therefore, this can rate a building of any era using the same method.
pp Other modifications to Appendix G include: elevator, motor, and refrigeration baselines; changes to the baseline for existing building projects; as well as specific opaque assemblies for the baseline envelope model. Modeling rule changes were also made to heat pump auxiliary heat, economizer shutoff, lighting controls, humidification systems, cooling towers, and the simulation of preheat coils.
Additional structural changes include:
pp Reference Standard Reproduction Annex 1 at the end of the document. This annex is designed to contain extracts from
other references that are published with Standard 90.1 for the convenience of users. At present, the only standard this pertains to is ANSI/ASHRAE Standard 169, Climatic Data for Building Design Standards. Section 5.1.4 now cites this standard as the source for climatic data therefore extractions of tables and figures from Standard 169-2013 are included in Annex 1
pp Addition of 2 weather zones 0 A/B in all prescriptive requirements tables to correspond with Standard 169.
The cost is $119, ASHRAE members ($140, non-members). To order,
visit www.ashrae.org/bookstore or contact ASHRAE Customer Contact
Center at 1-800-527-4723 (United States and Canada) or 404-636-8400
(worldwide) or fax 678-539-2129.
About ASHRAE
ASHRAE, founded in 1894, is a global society advancing human
well-being through sustainable technology for the built environment.
The Society and its more than 56,000 members worldwide focus on
building systems, energy efficiency, indoor air quality, refrigeration
and sustainability. Through research, standards writing, publishing,
certification and continuing education, ASHRAE shapes tomorrow’s
built environment today.
For more information, visit www.ashrae.org/news.
Chiller & Cooling Best Practices is published quarterly and mailed together with Compressed Air Best Practices®. Compressed Air Best Practices is published monthly except January-February combined by Smith Onandia Communications LLC, 37 McMurray Rd. Suite 106, Pittsburgh, PA 15241. Periodicals postage paid at Pittsburgh, PA and additional mailing offices. POSTMASTER: Send address changes to: Compressed Air Best Practices, 37 McMurray Rd., suite 106, Pittsburgh, PA 15241.
Compressed Air Best Practices® is a trademark of Smith Onandia Communications, LLC. Publisher cannot be held liable for non-delivery due to circumstances beyond its control. No refunds. SUBSCRIPTIONS: Qualified reader subscriptions are accepted from compressed air professionals, plant managers, plant engineers, service and maintenance managers, operations managers, auditors, and energy engineers in manufacturing plants and engineering/consulting firms in the U.S. Contact Patricia Smith for subscription information at tel: 412-980-9902 or email: [email protected]. REPRINTS: Reprints are available on a custom basis, contact Patricia Smith for a price quotation at Tel: 412-980-9902 or email: [email protected]. All rights are reserved. The contents of this publication may not be reproduced in whole or in part without consent of Smith Onandia Communications LLC. Smith Onandia Communications LLC. does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. Printed in the U.S.A.
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Cooling Towers • Central Plant Chillers • Cooling System Components
Sustainable Energy & Water Savings with Chiller & Cooling Best PracticesChiller & Cooling Best Practices is a technical magazine dedicated to discovering Energy and Water Savings in industrial chiller and cooling systems. Our editorial focus is on case studies and technical articles where application and system knowledge drives technology selection, creating
energy savings in projects delivering excellent ROI’s.
“ The brewery saw savings, over mechanical cooling, of 85% when able to use a 100% free-cooling chiller during the coldest months.”
– Rich Whitmore, President/CEO, Motivair Corporation (feature article in August 2016 Issue)
“ Demand for VSD is growing as the vast majority of industrial and HVAC installations are part-load.”
– Roger Richmond-Smith, CEO, Smardt Chiller Group (feature article in August 2016 Issue)
From Chillers, Dry Coolers and Cooling Towers to Hydronic Specialties and Master ControlsOur readers embrace Sustainability as a profitable business opportunity. We believe the industrial process cooling and HVAC installed base to be at a tipping point – one where “energy and water retrofits” will fuel a new era of market growth, similar to what we’ve seen in the compressed air industry. Better applying more varied cooling technology combinations to better understood partial-load demand profiles will fuel system improvements. This will combine with optimizing system components and using master controllers to further improve efficiencies.