This CIR is requesting approval of a proposed Exception Calculation Methodology (ECM) for energy savings in process-dominated manufacturing facility.
The project consists of a consumer products manufacturing facility. The energy required for the manufacturing process exceeds an estimated 90% of the facility's total energy load, and includes both electricity and natural gas.
The Project Client has made several energy savings improvements to the manufacturing process above and beyond standard practice for this industry. As a result of these changes, the new process consumes approximately 15% less energy per produced unit than the industry standard approach. Due to the building's high percentage of process loads, these new improvements will significantly reduce the project building's overall energy consumption. In addition to this, the Project Client will install efficient process steam boilers and an improved process chilled water system to achieve additional energy savings for both process and facilities loads.
Since the industrial energy use associated with specific manufacturing processes are not covered by ASHRAE 90.1-2007, an alternative compliance path must be established.
The Exceptional Calculation Methodology (ECM) will be used to demonstrate process energy savings. Please verify that the following ECM path may be used for the building process loads.
1. Energy Baseline Model - Manufacturing Process:
a. Process Steam: The baseline boiler efficiency is established utilizing Table 6.8.1F from ASHRAE 90.1-2007. Project Client has established the boiler capacity as >2,500,000 btu/hour and type as natural gas forced draft. Per Table 6.8.1F the baseline boiler efficiency will be 79%.
b. Process Chilled Water: The baseline chiller efficiency is established utilizing Table 6.8.1C from ASHRAE 90.1-2007. Project Client has established the chiller capacity as >300 tons and type as water cooled centrifugal. Per Table 6.8.1C the baseline chiller efficiency will be 6.40 IPLV.
c. Process Pumps: The baseline uses modulating valves on constant speed pumping systems to control flow for several processes. Using this method of adjusting flow for these types of systems is the industry standard.
d. Vacuum Pumps: The baseline for process vacuum pumps is conventional liquid ring vacuum pumps. This is the industry standard method in this type of manufacturing facility.
e. Drying System: The baseline uses air handling fans with variable inlet vane control for hot air control. This is the industry standard method for this process at manufacturing facilities of this type.
2. Proposed Design Model - Manufacturing Process:
a. Process Steam: The proposed design boiler efficiency, including stack economizers, is 85%. Project Client can obtain from the boiler and economizer manufacturers a detailed efficiency analysis report to demonstrate the boiler efficiency.
b. Process Chilled Water: The proposed design chiller efficiency is 6.69 IPLV. Additionally, the intent is to take credit for the energy savings from recovery of chiller condenser heat for use in the manufacturing process. Project Client has chiller manufacturer cut sheet data to support chiller efficiency and condenser heat recovery.
c. Process Pumps: The proposed design pumps use variable frequency drives to control flow. Project Client has a comprehensive list of pump parameters, along with energy savings calculation.
d. Vacuum Pumps: The proposed design uses an innovative system that uses 33% less electricity than the industry standard baseline. Since the technology is proprietary, Project Client will submit a brief description of the source of energy savings with supporting calculations, but no detailed cut sheets will be included.
e. Drying System: The proposed design consists of a proprietary drying system that uses 60% less energy than the industry standard baseline. Project Client will submit a brief description of the source of energy savings with supporting calculations, but no detailed cut sheets will be included since the technology is proprietary.
The following information will be submitted for each ECM under EA p2:
1. Detailed narrative establishing the baseline technologies, through either ASHRAE 90.1-2007 or industry standard practice
2. Detailed narratives and cut sheets describing non-proprietary equipment (items a, b, c)
3. Brief description of source of energy savings for proprietary technologies (items d, e)
4. Annual energy savings (Btu/year) and energy cost savings ($/year) calculations
The project team is inquiring about documenting improvements in a process-energy-intensive manufacturing plant. Generally, equipment covered by ASHRAE 90.1 requirements can be modeled according to ASHRAE 90.1 Appendix G requirements regardless of whether it serves standard building loads, process loads, or a combination of both. If the equipment is either being used in a manner that is incompatible with ASHRAE 90.1 requirements or is equipment not regulated by ASHRAE 90.1, project teams should compare the proposed design to the industry standard by documenting three facilities built within the last five years that have constant speed pump controls, by referencing current utility incentive programs for new construction that incentivize variable speed pumps serving this type of equipment, or by providing published or monitoring studies justifying that this is indeed standard practice. All process energy savings must still be documented using the Exceptional Calculation Methodology (ECM) for review.
The ruling regarding the proposed methodology for the baseline and proposed case proposals for each process efficiency measure using the Exceptional Calculation Methodology (ECM) is documented below:
a. Process Steam: Modeling baseline boilers as meeting the efficiencies listed in ASHRAE 90.1 Table 6.8.1F is acceptable.
b. Process Chillers: Modeling baseline chillers as meeting the efficiencies listed in ASHRAE 90.1 Table 6.8.1C is acceptable. Chilled water and condenser water parameters must be modeled identically in the baseline and design models, or documentation of industry standard practice must be provided in accordance with the above.
c. Process pumps: Modeling baseline pumps as meeting the minimum prescriptive requirements in ASHRAE 90.1 is acceptable. Pumps operating differently than those used for building HVAC systems must provide documentation of industry standard practice in accordance with the above.
d. Vacuum pumps: Vacuum pumps are not covered by ASHRAE 90.1 and must be modeled identically in the baseline and design model. Alternatively, provide documentation of industry standard practice in accordance with the above.
e. Drying System: Drying systems are not covered by ASHRAE 90.1 and must be modeled identically in the baseline and design model. For components of the drying system that are regulated by ASHRAE 90.1 (such as fans) modeling these components according to the ASHRAE 90.1 minimum requirements in the baseline is acceptable. Alternatively, provide documentation of industry standard practice in accordance with the above.
Note: In all cases, for proprietary equipment used to claim energy savings documentation provided must show sufficient information to allow reviewers to independently confirm the savings claimed has been calculated correctly.
Related Addenda (Corrections & Interpretations)