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How to Improve Energy Efficiency & Reduce Maintenance
Getting the most from your energy management system
John WallaceEmerson Climate Technologies Retail Solutions
Discussion Topics
Introduction to an EMS
Focus on Energy
Getting Your Money’s Worth
And Beyond:What’s Next?
What Is an EMS?
Techniques to Reduce
Energy Consumption
Using All the Capabilities in State-of-
the-Art Systems
What’s Driving Next
Generation Systems
Development?
“Islands of Control” Integrated to Forma Complete Energy Management System
Individual Systems Tied Together Information Sharing Across
Systems Emergence of “Supervisory
Functions” Integration/Control Maturity Similar
to Auto Industry Evolution– Communication Technologies– More Sensors– Smarter Control– Use Data to Drive Actions
Supervisory System
HVAC
LightingREF
Other
Connecting the “Islands” Into an EMS
Layers and Functions of an EMS
• Remote User Interface• Site Information• Data Feed
Key Elements
• On-site User Interface• User Management• Data Logging• Alarming• Cross-system Coordination
• Control Algorithms• Inputs and Outputs• Sensors and Transducers• Equipment Interface
Integration of Third Party Equipment Leverages EMS Functionality to Provide Control and Information
Benefits• Common User Interface Across Site• Remote Access• Normalized Information (Alarms, Logs, etc.)
Using EMS Infrastructure• Operational Visibility
53%
6%
41%
HVAC REFR OTHER
70%
27%
4%
ECHELON MODBUS BACNET
BY PROTOCOLBY TYPE
Third Party Device Statistics
Note: Statistics based on Emerson’s E2 support (113 devices)
< 1 yr
> 4 yr
< 2 yr
EMS Supports Different Control Architectures
Installation Costs Similar Across Architectures
Case Control Architecture Simplifies Electrical and Refrigeration Installation
Centralized Control Case Control
• Control Elements at RefrigerationRack or Electrical Panel
• “Home Runs” for Sensors • Separate Electrical Circuits for Loads
• Control Elements at Case• Communication “Daisy Chain”
to Supervisory System• Load Control at Refrigeration Case
Case Control Architecture Reduces Field Wiring and Provides Electrical Savings
• Reduce Line Voltage Wiring– Reduce Branch Feeder Wiring by 30% or More
– Reduce or Eliminate Circuit Panels and Breakers
– Reduce Branch Feeder Distance: Distributed Design
– Eliminate Line Voltage Control Home Runs to Rack
– Simplified Power Connections at Case
• Reduce Low Voltage Wiring– Eliminate Low Voltage Control Home Runs to Rack
– Simplified Low Voltage Control Connections at Case
• Reduce Case Field Wiring– OEM Factory Wiring of Control and Sensors
– Facilitates Factory Checkout Versus Field Troubleshooting
Utilizing Case Controls Reduces Energy and Maintenance Costs
Reduce Maintenance Costs– Additional Sensors Enable Remote
Diagnostics and Facilitate Faster and More Reliable Troubleshooting
– No Seasonal Expansion Valve/EPR/ Temperature Adjustments
Use Technology to Supplement Technicians
• Reduce Energy Used atthe Evaporator– Precise Control Eliminates
Mechanical Valve “Parasitic Losses”
– Optimized Valve Control Ensures Refrigeration System Operatingat Peak Efficiency
• Reduce Energy Used atthe Rack– Electronic Valve Facilitates Much
Lower Condensing Pressures
– Approximately 1% of Compressor Energy Savings per 2 psig Increase in Suction
Call Center Diagnoses ConditionRelevant
Information Providedto Tech
Store Equipment Provides
Data
Remote Troubleshooting
Discussion Topics
Introduction to an EMS
Focus on Energy
Getting Your Money’s Worth
And Beyond:What’s Next?
What Is an EMS?
Techniques to Reduce
Energy Consumption
Using All the Capabilities in State-of-
the-Art Systems
What’s Driving Next
Generation Systems
Development?
CEC Title 24 Impact On Supermarket Refrigeration Systems
Released in 2012 Broader Than CA Refrigeration Impact
– Floating Head Pressure– Floating Suction Pressure– Mechanical Subcooling– Display Case Lighting– Heat Recovery
Lighting Impact – Automatic Controls
Energy Management and Maintenance Are Keys to Operational Excellence and Profitability
Source: FMI 2000 supermarket study referenced by allbusiness.com
The Four Stages of Energy Reduction
Energy Reduction Is a Continuous Process
Utilize EMS to Limit Peak Demand
kW
Time
Application Typical Shed Action
HVAC Applications Raise Cooling Setpoints, Lower Heating Setpoints
Sensor Control Raise or Lower Cut in/Cut Out
Lighting Stage Circuits off
Time
Shed
Setpoint
Demand Without Shed Demand With Shed
Advanced Shed Algorithms (i.e., Rotational Shed) Allow Strategies Such as “Comfort First” to Minimize Disruptions
Peak Sets Demand Charges
• EMS MonitorsDemand
• As Demand Approaches Preset Level, EMSSheds Loads
“Watching” Energy Management Settings Regularly Will Prevent Energy Leakage
Energy Management
Systems
HVAC/R/LEquipment
Technician On-site to Fix
a Problem
Changes Made to EMS Settings
Impact on Operational
Performance
Check to Find “Band-Aids” Left in Place
Impact Energy Usage
Periodic Analysis Required to Ensure System Optimizations Not Compromised
Common EMS Issues That CanImpact Energy Usage
Fixture Settings– Check Case Temp Setpoints to Ensure Proper Settings
Sensor Offsets– Ensure Temperature Sensors Are Not Offset, Masking a Problem
Check Proper Operation of Liquid Level Sensors– Low Refrigerant Levels Increase Energy Usage
Humidity Sensors Affect HVAC and ASW Algorithms– Check to Ensure Correct Operation
Lighting Schedules and Overrides– Ensure Lighting Schedules Are Set Properly and No Overrides Are Present
Light Level Sensors Operational– Failed Sensors Could “Fail Over” to Schedules
Ensure There Are No Overlapping Defrost Schedules
Implement Floating Suction PressureControl to Continuously Optimize Operation
Refrigeration Rack
Circuit 1
EMS
Suction Pressure Setpoint Fixed
Fixed Strategy
Refrigeration Rack
Circuit 1
Suction Pressure Setpoint Variable
Floating Strategy
Temp Feedback
Fixed Strategy Holds Suction Pressure Setpoint, Regardless of Load Floating Strategy Uses Feedback Loop to Change Pressure Setpoint
Based on Load Requirements Typically No Additional Hardware Required to Enable
Use Floating Suction Setpoint to Ensure ESR Control Continually Optimized
Optimized to Keep at Least One Valve Completely Open Based on Load
Floating Head Pressure Optimizes Condenser Operation Based on Ambient (TD)
TD (Ambient Following) Optimizes Condenser Control Based on Ambient Temperature
Target Condensing Temperature Set to Ambient Temperature Witha Fixed Offset
Fans Cycled to Maintain Target Temperature With Appropriate Overrides
Can Be Combined With Variable Speed Control Fans to Increase Efficiency
Studies Show Potential to Save Approximately 7% (Total Refrigeration Power) to 13% (With VSDs), Depending on Location
Defrost Strategies Can Result in Significant Savings as Well as Other Benefits
Normal “Timed” Defrost On-Demand Defrost
Implementation of Demand Defrost Results in 20% Energy Savings Versus Traditional Defrost Methods
Fewer Defrosts
Discussion Topics
Introduction to an EMS
Focus on Energy
Getting Your Money’s Worth
And Beyond:What’s Next?
What Is an EMS?
Techniques to Reduce
Energy Consumption
Using All the Capabilities in State-of-
the-Art Systems
What’s Driving Next
Generation Systems
Development?
EMS Provides Operational Visibility Utilizing Control Data
Data Correlated to Show Top 10 Sites Generating
Alarms Across EnterpriseAlarm Drilldown Shows
Problem Area at Site
EMS Generates Alarm Data
Technician Dispatched to Address
Problem
1
2
3
4
Use EMS Alarm Information toPrioritize Maintenance Activities
Use the EMS to Simplify Food Safety Initiatives
EMS
Installed Today
Inspectors
AND Provide Information for Multiple Functions
Food Safety Managers
Store Managers
Data Servers
Refrigeration Control Systems Monitor and Control Food
Temperature
Temperature Logs
• Process Improvement• Regulatory Compliance• Problem Identification
Discussion Topics
Introduction to an EMS
Focus on Energy
Getting Your Money’s Worth
And Beyond:What’s Next?
What Is an EMS?
Techniques to Reduce
Energy Consumption
Using All the Capabilities in State-of-
the-Art Systems
What’s Driving Next
Generation Systems
Development?
Ten Trends in Smart Buildings
1. Building Energy Management Hits the Cloud
2. Co-opetition Is on the Rise in the Building Industry
3. Targeted Acquisitions Help Key Players DeliverEnergy Services
4. Demand for Smart Building Products Will Soar (China)
5. U.S. Energy Companies (ESCOs) Turn to Federal Sector
6. Building Communications Protocols Are Converging
7. Demand Response Is Shifting Into Automatic
8. Submeters Find New Opportunities in Smarter Buildings
9. Building Information Modeling (BIM) Is Transformingthe Design Process
10. The Interface Between Smart Building and the SmartGrid Is Blurring
Source: Pike Research Report, 2012
Trends Drive Innovation in Four Key Areas
User Interface and Usability Integration
Cloud Connectivity Extensibility and “Apps”
The Web and Apps Set the Bar
“IT Friendly” and IOT Will Be the Rule Top Level Sub-system Integration Will
Drive Interoperability Wireless Technology Will Drive
Installation Costs Down (Especially for Retrofits)
Seamless Data Storage Provisioning and
Controller Management Automate Many Tasks
Enables Enterprise Analytics and “Big Data”
1 2
3 4
Thank You!
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.
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