Supermarket Chain’s Supermarket Chain’s Experience with Experience with

GREENing CKV OPERATIONS GREENing CKV OPERATIONS

byby Robert Ajemian, MSPH Robert Ajemian, MSPH

President - Green Kitchen Designs Inc.President - Green Kitchen Designs Inc.

www.GreenKitchenDesigns.com AHR EXPO

BOOTH #2731

TAKE –HOME MESSAGETAKE –HOME MESSAGE1) GREEN CKV designs 1) GREEN CKV designs CANCAN and and DODO work work

for large supermarket commercial kitchensfor large supermarket commercial kitchens

2) A myriad of challenges 2) A myriad of challenges WILLWILL arise that arise that require require ONGOINGONGOING commitment throughout commitment throughout the construction installation processthe construction installation process

3) Traditional plan and spec model deficient- 3) Traditional plan and spec model deficient- Empowerment of a CKV professional is Empowerment of a CKV professional is IMPERATIVEIMPERATIVE and awarding and awarding CLEARCLEAR points points for LEED accreditation is overduefor LEED accreditation is overdue

OVERVIEWOVERVIEW1.1. BackgroundBackground2.2. Design ChallengeDesign Challenge3.3. What innovations/knowledge was used What innovations/knowledge was used

to design GREEN CKV systemsto design GREEN CKV systems4.4. What additional green concepts were What additional green concepts were

used from store #1 through store #2used from store #1 through store #25.5. Challenges to implement the designsChallenges to implement the designs6.6. OutcomesOutcomes7.7. Advice to Concerned PartiesAdvice to Concerned Parties

BackgroundBackground

LARGE NATIONAL CHAIN WITH LARGE NATIONAL CHAIN WITH WARM & FUZZY ORGANIC FEELING WARM & FUZZY ORGANIC FEELING FEATURES LARGE VARIETY OFFEATURES LARGE VARIETY OF

IN-STOREIN-STORE PREPARED FOODS PREPARED FOODS

DECENTRALIZED MANAGEMENTDECENTRALIZED MANAGEMENT SENSITIVE ALTERNA-DUDE STAFF SENSITIVE ALTERNA-DUDE STAFF DIFFICULT TO ESTABLISH WHO THE DIFFICULT TO ESTABLISH WHO THE

DECISION-MAKER WASDECISION-MAKER WAS

BackgroundBackground

““GREEN” ARCHITECTURAL MANDATE AND GREEN” ARCHITECTURAL MANDATE AND PRODUCT OFFERING , BUT…PRODUCT OFFERING , BUT…

NO GREEN ENGINEERING MANDATENO GREEN ENGINEERING MANDATE CKV CONSULTANT SUGGESTED GREEN CONCEPTSCKV CONSULTANT SUGGESTED GREEN CONCEPTS

NO FORMAL ATTEMPT AT LEED RATINGNO FORMAL ATTEMPT AT LEED RATING EVEN IF SO, LACK OF CKV IN NEW EVEN IF SO, LACK OF CKV IN NEW

CONSTRUCTION HINDERS PROCESSCONSTRUCTION HINDERS PROCESS

ENGINEER USED GREEN CKV CONSULTANT ENGINEER USED GREEN CKV CONSULTANT TO DESIGN JOB BUT……..TO DESIGN JOB BUT……..

CKV CONSULTANT NEVER VESTED WITH ANY CKV CONSULTANT NEVER VESTED WITH ANY AUTHORITY TO PROJECT MANAGERSAUTHORITY TO PROJECT MANAGERS

DESIGN CHALLENGE - HOODSDESIGN CHALLENGE - HOODS SEVERAL TYPES OF COOKING SEVERAL TYPES OF COOKING

MAIN 36’ PREPARATION KITCHENMAIN 36’ PREPARATION KITCHEN HOODS ON STORE FLOORHOODS ON STORE FLOOR

SUSHI BAR /ROTISSERIE/ SMOKER/ TRATTORIASUSHI BAR /ROTISSERIE/ SMOKER/ TRATTORIA

EXPENSIVE ELECTRIC COSTS-17c KwhEXPENSIVE ELECTRIC COSTS-17c Kwh Need to minimize exhaust CFMNeed to minimize exhaust CFM

HOODS FOUND ON TWO FLOORSHOODS FOUND ON TWO FLOORS TWO SYSTEMS REQUIRED - NFPA 96 TWO SYSTEMS REQUIRED - NFPA 96

DUCT SPACE AT A PREMIUMDUCT SPACE AT A PREMIUM TYPE I & II HOODS COMBINED IN SAME SYSTEMTYPE I & II HOODS COMBINED IN SAME SYSTEM

DESIGN CHALLENGE- SMOKE DESIGN CHALLENGE- SMOKE AND ODOR CONTROLAND ODOR CONTROL REQUIRED DESPITE ROOF DISCHARGEREQUIRED DESPITE ROOF DISCHARGE

HIGH POPULATION DENSITY-MANHATTANHIGH POPULATION DENSITY-MANHATTAN PREVIOUS HISTORY OF COMPLAINTS PREVIOUS HISTORY OF COMPLAINTS

FROM UNCONTROLLED STORES FROM UNCONTROLLED STORES

PROBLEMATIC PAST EXPERIENCE WITH PROBLEMATIC PAST EXPERIENCE WITH POLLUTION CONTROL EQUIPMENT POLLUTION CONTROL EQUIPMENT UNDER SIZED UNITS LEAD TO COMPLAINTSUNDER SIZED UNITS LEAD TO COMPLAINTS

MAIN DESIGN GOALSMAIN DESIGN GOALS UTILIZE MINIMUM AMOUNT OF EXHAUST AIR UTILIZE MINIMUM AMOUNT OF EXHAUST AIR

VOLUME TO EFFECTIVELY CAPTURE VOLUME TO EFFECTIVELY CAPTURE COOKING EMISSIONS AND MINIMIZE COOKING EMISSIONS AND MINIMIZE SYSTEM COMPONENTSSYSTEM COMPONENTS

COMBINE TYPE I AND TYPE II SYSTEMS COMBINE TYPE I AND TYPE II SYSTEMS TO CONSERVE DUCT SPACETO CONSERVE DUCT SPACE

USE PROPERLY SIZED POLLUTION USE PROPERLY SIZED POLLUTION CONTROL EQUIPMENT WITH CONTROL EQUIPMENT WITH RESERVE CAPACITYRESERVE CAPACITY TO ACCOMMODATE FUTURE EXPANSIONTO ACCOMMODATE FUTURE EXPANSION TO MINIMIZE PROBALITY OF COMPLAINTSTO MINIMIZE PROBALITY OF COMPLAINTS MORE FOCUS ON OPERATING vs. CAPITAL COSTMORE FOCUS ON OPERATING vs. CAPITAL COST

DESIGN SOLUTION - HOODSDESIGN SOLUTION - HOODS MAIN KITCHEN HOODS - HIGH VELOCITY MAIN KITCHEN HOODS - HIGH VELOCITY

FRONT SLOT HOOD WAS SELECTED WITH FRONT SLOT HOOD WAS SELECTED WITH ADJUSTABLE BAFFLESADJUSTABLE BAFFLES ESTIMATED 40% REDUCTION OVER IMC ESTIMATED 40% REDUCTION OVER IMC

VENTILATION RATESVENTILATION RATES

FLOOR HOODS- WERE FILTER HOODSFLOOR HOODS- WERE FILTER HOODS LESS EXPENSIVE LESS EXPENSIVE HOODS HAD ADJUSTABLE BAFFLE “BLAST GATE” HOODS HAD ADJUSTABLE BAFFLE “BLAST GATE”

TO HELP TO BALANCE OUT SYSTEMTO HELP TO BALANCE OUT SYSTEM ADVANCED HOOD FILTERS USED TO REDUCE ADVANCED HOOD FILTERS USED TO REDUCE

LOADING ON ELECTROSTATIC PRECIPITATORLOADING ON ELECTROSTATIC PRECIPITATOR

DESIGN SOLUTION-HOODS DESIGN SOLUTION-HOODS

WHERE PHYSICALLY POSSIBLE; PARTIAL WHERE PHYSICALLY POSSIBLE; PARTIAL SIDE PANELS WERE INCLUDEDSIDE PANELS WERE INCLUDED THESE WERE LATER DISCARDED BY ARCHITECT THESE WERE LATER DISCARDED BY ARCHITECT

WHO DIDN’T LIKE THEIR APPEARANCEWHO DIDN’T LIKE THEIR APPEARANCE

WHERE PHYSICALLY POSSIBLE; HOOD WHERE PHYSICALLY POSSIBLE; HOOD DEPTHS WERE INCREASEDDEPTHS WERE INCREASED AGAIN ARCHITECT DISALLOWED THIS ON THE AGAIN ARCHITECT DISALLOWED THIS ON THE

MAIN MARKET FLOORMAIN MARKET FLOOR

MAIN KITCHEN HOODMAIN KITCHEN HOOD

DESIGN SOLUTIONS –DESIGN SOLUTIONS –REPLACMENT / MAKE-UP AIRREPLACMENT / MAKE-UP AIRFIRST STORE ; COOLING WAS SPECIFIED FOR FIRST STORE ; COOLING WAS SPECIFIED FOR

THE MAIN KITCHEN THE MAIN KITCHEN FRONT DISCHARGE GRILLS WERE USED TO FRONT DISCHARGE GRILLS WERE USED TO

THRUST COOL AIR INTO THE KITCHEN (75X18’)THRUST COOL AIR INTO THE KITCHEN (75X18’) 95% OF AIR WAS REPLACED95% OF AIR WAS REPLACED

SECOND STORE; KITCHEN CONNECTED TO SECOND STORE; KITCHEN CONNECTED TO MAIN STORE MAIN STORE SO 60% MINIMALLY HEATED AIR WAS SO 60% MINIMALLY HEATED AIR WAS

DISCHARGED IN REAR PLENUMDISCHARGED IN REAR PLENUM BALANCE WAS SUPPOSED TO BE COOLED BALANCE WAS SUPPOSED TO BE COOLED

TRANSFER AIR FROM MAIN FLOOR TRANSFER AIR FROM MAIN FLOOR

95% MAKE-UP AIR95% MAKE-UP AIR

DESIGN SOLUTION – DESIGN SOLUTION – SMOKE AND ODOR CONTROLSMOKE AND ODOR CONTROL STORE HAD USED ELECTROSTATIC STORE HAD USED ELECTROSTATIC

PRECIPITATORS IN THE PAST BUT PRECIPITATORS IN THE PAST BUT THEY HAD BEEN UNDERSIZEDTHEY HAD BEEN UNDERSIZED

ELECTROSTATIC UNITS WERE SIZED FOR ELECTROSTATIC UNITS WERE SIZED FOR REDUNDANCY AND EXTRA CFM CAPACITYREDUNDANCY AND EXTRA CFM CAPACITY

BOTH STORES HAD 50-60% MID-RANGE BOTH STORES HAD 50-60% MID-RANGE EFFICIENT ADVANCED HOOD FILTERS TO EFFICIENT ADVANCED HOOD FILTERS TO REDUCE PRECIPITATOR LOADING/SERVICEREDUCE PRECIPITATOR LOADING/SERVICE

BOTH STORES USED VFD BOTH STORES USED VFD TO OPTIMIZE CFM TO OPTIMIZE CFM LENGHTHEN MOTOR LIFE LENGHTHEN MOTOR LIFE SMALLER HP MOTOR (STARTER COILS)SMALLER HP MOTOR (STARTER COILS)

FIRST STOREFIRST STORE USED DOUBLE PASS SYSTEM WITH EACH USED DOUBLE PASS SYSTEM WITH EACH

PASS RATED FOR 95% (0.3 UM) REMOVALPASS RATED FOR 95% (0.3 UM) REMOVAL CRITICAL BECAUSE ONE POWER SUPPLY CRITICAL BECAUSE ONE POWER SUPPLY

WENT BAD AND UNREPORTED FOR WENT BAD AND UNREPORTED FOR SEVERAL MONTHSSEVERAL MONTHS

DESIGN SOLUTION – DESIGN SOLUTION – SMOKE AND ODOR CONTROLSMOKE AND ODOR CONTROL

SECOND STORESECOND STORE

WENT TO SINGLE PASS AND MERV 17 CLASS I WENT TO SINGLE PASS AND MERV 17 CLASS I MEDIA FILTER SAFETY MEDIA FILTER SAFETY TO SAVE ON DETERGENT COSTSTO SAVE ON DETERGENT COSTS

DETERGENT COSTS WERE REDUCED BY 40% BUT DETERGENT COSTS WERE REDUCED BY 40% BUT GAINS PARTIALLY OFFSET BY COST OF MEDIA FILTERSGAINS PARTIALLY OFFSET BY COST OF MEDIA FILTERS

WENT TO DOUBLE PASS CARBON TO DOUBLE WENT TO DOUBLE PASS CARBON TO DOUBLE CARBON LIFECARBON LIFE

FAN AND VFD WERE WISELY CHOSEN WITH NEXT FAN AND VFD WERE WISELY CHOSEN WITH NEXT SIZE MOTOR (25 hp INSTEAD OF 20 Hp)- EXTRA SIZE MOTOR (25 hp INSTEAD OF 20 Hp)- EXTRA CAPACITY (THANK GOODNESS)CAPACITY (THANK GOODNESS)

DESIGN SOLUTION – DESIGN SOLUTION – SMOKE AND ODOR CONTROLSMOKE AND ODOR CONTROL

DOUBLE PASS ELECTROSATIC DOUBLE PASS ELECTROSATIC PRECIPITATORSPRECIPITATORS

OUTCOMEOUTCOME

FIRST STORE WAS QUITE SUCCESSFUL IN FIRST STORE WAS QUITE SUCCESSFUL IN ENERGY SAVINGS AND TO DATE NO ODOR ENERGY SAVINGS AND TO DATE NO ODOR COMPLAINTS THOUGH MAINTENANCE COMPLAINTS THOUGH MAINTENANCE COSTS ARE HIGHER- VERY GOOD RESULT COSTS ARE HIGHER- VERY GOOD RESULT WITH CFM REDUCTION-LESS THAN DESIGNWITH CFM REDUCTION-LESS THAN DESIGN

SECOND STORE WAS MORE SUCCESSFUL SECOND STORE WAS MORE SUCCESSFUL IN CONTROL OF COOKING EMISSIONS IN CONTROL OF COOKING EMISSIONS BECAUSE OF REDUCED FILTRATION COSTS- BECAUSE OF REDUCED FILTRATION COSTS- LESS SO IN ENERGY SAVINGS DUE TO POOR LESS SO IN ENERGY SAVINGS DUE TO POOR DUCTWORK and BALANCING DIFFICULTIESDUCTWORK and BALANCING DIFFICULTIES

OUTCOMEOUTCOME WHAT CHANGED FOR WORSE?WHAT CHANGED FOR WORSE? DESIGN – NO DESIGN – NO

IT WAS IMPROVEDIT WAS IMPROVED PRODUCT MANUFACTURER-YESPRODUCT MANUFACTURER-YES

QUALITY AND SUPPORT DECREASEDQUALITY AND SUPPORT DECREASED CONTRACTOR- YESCONTRACTOR- YES

POOR DUCTWORK AND WORK QUALITYPOOR DUCTWORK AND WORK QUALITY OVERSIGHT MANAGEMENT-YESOVERSIGHT MANAGEMENT-YES

STORE CONSTRUCTION MANAGER STORE CONSTRUCTION MANAGER WAS INEXPERIENCEDWAS INEXPERIENCED

WHERE’S THE WHERE’S THE GREENGREEN ? ? (INITIAL CAPITAL COSTS)(INITIAL CAPITAL COSTS)

ITEMITEM NET COST NET COST BASIS/EFFECTBASIS/EFFECT

DOLLAR DOLLAR AMOUNTAMOUNT

HOODSHOODS +100%+100% +$20,000+$20,000

PRECIPT/FANPRECIPT/FAN 5000 CFM LESS5000 CFM LESS -$ 20,000$ 20,000

EXHAUST DUCTEXHAUST DUCT $60/LF$60/LF -$ 12,000-$ 12,000

FIRE WRAPFIRE WRAP $40/LF$40/LF -$ 8,000-$ 8,000

MAKEUP AIR UNITMAKEUP AIR UNIT $1000/Ton AC (12 )$1000/Ton AC (12 ) -$ 12,000-$ 12,000

SUPPLY DUCTSUPPLY DUCT $10/LF$10/LF -$ 2,000-$ 2,000

DUCT LABORDUCT LABOR $100/LF (Union)$100/LF (Union) -$ 20,000-$ 20,000

TOTAL CAPITAL COST SAVINGSTOTAL CAPITAL COST SAVINGS -$ 60,000-$ 60,000

EST. ANNUAL HEATING EST. ANNUAL HEATING SAVINGS- SAVINGS- $4927$4927

Description Rev-Low Exhaust Straight Exhaust Total Hood Exhaust 7672 CFM 12600 CFM Heated Kitchen Air 7672 CFM 12600 CFM Kitchen Heater Capacity 646290 BTU/hr. 884520 BTU/hr. Energy Cost Data Total Annual Heating Cost $7,670.00 $12,597.00 Energy Savings When Using Rev-Low $4,927.00

HEAT ANNUAL COST CALCULATION The formula for calculating the cost of heated makeup air is: Annual Cost = Vol(CFM) x 1.09 x Degree Days x hrs/day x Energy Cost/Heating Efficy Where: Degree Days 1853 Winter Design Temperature (F) -10 degrees F Hours/day 22 Energy Cost ($/MM Btu) $18.00 MAU Heating Efficiency 0.8 Building Heating Efficiency 0.8 Weather data extracted from NOAA United States Climatic Norms 1971 - 2001 Climotographic of the United States No. 81 Supplement No.2

Est. Annual Cooling Savings-$ Est. Annual Cooling Savings-$ 36363636Energy Cost Data

Annual Cooling Cost $5659.00 $9296.00

Energy Savings When Using Rev-Low $3636.00

COOLING ANNUAL COST CALCULATION Cooling Degree Days @ 60F (for kitchen design below 80F) 1776

Hours/day operation 22 Energy Cost $KW/HR $0.17 AC Correction Factor 1.00 Coefficient of Performance (COP) 3.00 Kitchen Design Temperature (°F) 0 Kitchen is not air conditioned Summer Dry Bulb Temperature (°F) 88 The formula for calculating the cost of cooling makeup air is: Annual Cost = CFM x 1.09 x Degree Days x hrs/day x Energy Cost x AC /(COP x 3413) CFM = The supply volume of fresh air to be cooled Degree Days = Cooling Degree Days at temperature selected Hours/day = The average operating hours/day Energy Cost = Energy Cost ($/KWHR) AC = AC Correction Factory (1) COP = Coefficient of Performance of the cooling system (3)

Weather data extracted from NOAA United States Climatic Norms 1971 - 2001 Climotographic of the United States No. 81 Supplement No.2

FAN AND TOTAL ESTIMATED ANNUAL FAN AND TOTAL ESTIMATED ANNUAL OPERATING ENERGY SAVINGSOPERATING ENERGY SAVINGS

FAN OPERATING ENERGY SAVINGS –FAN OPERATING ENERGY SAVINGS – DECREASE VOLUME VS INCREASE S.P.DECREASE VOLUME VS INCREASE S.P. 7672 CFM@6”w.g. vs 12600 CFM@5”w.g.7672 CFM@6”w.g. vs 12600 CFM@5”w.g. Approximately 10 HP vs 14 HP for utility set typeApproximately 10 HP vs 14 HP for utility set type

TOTAL EST. ANNUAL ENERGY SAVINGSTOTAL EST. ANNUAL ENERGY SAVINGSHEATING - $ 4,927HEATING - $ 4,927COOLING - $ 3,636COOLING - $ 3,636FAN - FAN - $ 4,000$ 4,000

TOTAL $ 12,563TOTAL $ 12,563

How can we improve –How can we improve –OWNERS?OWNERS?

EITHER COMMIT TO GREEN DESIGN EITHER COMMIT TO GREEN DESIGN AND ITS COSTS ………….OR DON’TAND ITS COSTS ………….OR DON’T

INSTRUCT ARCHITECTS TO SEEK INSTRUCT ARCHITECTS TO SEEK GREEN DESIGNS FROM CKV EXPERTS GREEN DESIGNS FROM CKV EXPERTS

EXPECT TO PAY FOR A QUALTY EXPECT TO PAY FOR A QUALTY DESIGN AND JOBDESIGN AND JOB

DON’T AUTOMATICALLY CAPITULATE DON’T AUTOMATICALLY CAPITULATE WHEN A LOW BIDDER WINS WITH WHEN A LOW BIDDER WINS WITH SUBSTITUTED EQUIPEMENTSUBSTITUTED EQUIPEMENT

How can we improve - How can we improve - ARCHITECTS?ARCHITECTS? ARHITECTS NEED TO EITHER GRASP NEWER ARHITECTS NEED TO EITHER GRASP NEWER

CKV DESIGN ENHANCEMENTS OR AT LEAST CKV DESIGN ENHANCEMENTS OR AT LEAST BE OPEN TO CONSIDER THEIR VALUE vs BE OPEN TO CONSIDER THEIR VALUE vs AESTHETICSAESTHETICS

SIDE PANELSSIDE PANELS DEEPER HOODSDEEPER HOODS PLACEMENT OF HOODSPLACEMENT OF HOODS MAKEUP AIR DELIVERY CONCEPTSMAKEUP AIR DELIVERY CONCEPTS

PUSH FOR LEED POINTS THROUGH PUSH FOR LEED POINTS THROUGH AIA/USGBC FOR WELL-DESIGNED CKVAIA/USGBC FOR WELL-DESIGNED CKV

How can we improve- How can we improve- ENGINEERS?ENGINEERS?

ENGINEERS GET UP TO SPEED NOW ENGINEERS GET UP TO SPEED NOW or EMPOWER YOUR CKV DESIGNERor EMPOWER YOUR CKV DESIGNER

USE THAT DUCTILATOR- IT’S EASY USE THAT DUCTILATOR- IT’S EASY

DO NOT HESITATE TO REJECT DO NOT HESITATE TO REJECT POORLY DESIGNED DUCT SHOP DWGSPOORLY DESIGNED DUCT SHOP DWGS

ENFORCE YOUR DESIGNS WITH ENFORCE YOUR DESIGNS WITH CONTRACTORS CONTRACTORS

How can we improve – How can we improve – MANUFACTURERS/CONTRACTORSMANUFACTURERS/CONTRACTORS

MANUFACTURERS MANUFACTURERS NEED TO PROVIDE MORE ACCURATE S.P. LOSS NEED TO PROVIDE MORE ACCURATE S.P. LOSS

DATA THROUGH THEIR EQUIPMENTDATA THROUGH THEIR EQUIPMENT NEED TO PROVIDE BETTER QUALITY CONTROL NEED TO PROVIDE BETTER QUALITY CONTROL BETTER SHIPPING PROTECTION FOR PRODUCTSBETTER SHIPPING PROTECTION FOR PRODUCTS

CONTRACTORSCONTRACTORS DO WHAT THEY HAVE AGREED TO DO IN A DO WHAT THEY HAVE AGREED TO DO IN A

CARING AND CONCERNED WAYCARING AND CONCERNED WAY STOP LYING!STOP LYING!

How Can We Improve –How Can We Improve –CKV EXPERTS AND ASHRAE CKV EXPERTS AND ASHRAE EMPHASIS THAT OUR ROLE IS MORE THAN EMPHASIS THAT OUR ROLE IS MORE THAN

JUST A VENDOR AND ASK ENGINEER TO JUST A VENDOR AND ASK ENGINEER TO ESTABLISH OUR AUTHORITY AND VALUEESTABLISH OUR AUTHORITY AND VALUE

SHARE ANY SUCCESSFUL ATTEMPTS FOR SHARE ANY SUCCESSFUL ATTEMPTS FOR LEED POINTS WITH COLLEAGUESLEED POINTS WITH COLLEAGUES

PERHAPS INSTITUTE A CERTIFICATION PERHAPS INSTITUTE A CERTIFICATION PROCESS FOR CKF DESIGNERSPROCESS FOR CKF DESIGNERS

HANG IN THERE- IT WILL GET BETTERHANG IN THERE- IT WILL GET BETTER

TAKE –HOME MESSAGETAKE –HOME MESSAGE 1) GREEN CKV designs CAN and DO 1) GREEN CKV designs CAN and DO

work in large commercial kitchenswork in large commercial kitchens

2) A myriad of problems exist that require 2) A myriad of problems exist that require attention in ADVANCE and power to attention in ADVANCE and power to solve as more inevitably come upsolve as more inevitably come up

3) Traditional plan and spec model falls 3) Traditional plan and spec model falls short- the attention and empowerment of short- the attention and empowerment of a CKV to the design team is necessary- a CKV to the design team is necessary- and it isn’t free and it isn’t free