How to Meet 2017/2020 Energy Regulations - Brian Buynacek Senior Refrigeration Engineer and Marketing Consultant Emerson - Emerson ...
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How to Meet 2017/2020 Energy Regulations U.S. Commercial Foodservice Ani Jayanth Brian Buynacek Foodservice Marketing Senior Refrigeration Engineer Manager and Marketing Consultant Emerson Emerson
Disclaimer 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.
DOE Equipment Regulations Survey
Commercial refrigeration Walk-in coolers and Automatic commercial
equipment freezers (WICF) ice makers
• Effective March 2017 on new • Effective January 2020 on new • Effective January 2018 on new
equipment equipment equipment
• CRE measured in kWh/24 -hour day • WICF measured in three major • ACIM measured in kWh/100 lbs ice
components
–Each equipment class assigned – Each equipment class assigned
• AWEF measured using AHRI-1250 equation
equation
testing standard
–Variable: Total Display Area (TDA) – Variable: H = harvest rate in
or volume –Each equipment class assigned
pounds per 24 hours
equation
–Variable: Q = system capacity
Industry Reach-In Solid Door Refrigerator Energy Draw
From 20% to 50% energy reduction required for systems, depending on class 5% to 25% energy reduction required
Source: Department of Energy
3
EPA’s Final Rule, July 20, 2015, and September 26, 2016
Changed listing status of certain HFCs*
Final Rule: July 20, 2015 2 Final Rule: September 26, 2016
1
Stand-Alone
Refrigerated
Remote
Remote MT < 2,200 MT ≥ 2,200 food Cold Very
Super- Super- condensi LT and Ice
Phase-out condensi BTU/hr. and not BTU/hr. with or processing and storage low-temp
market market ng unit LT MT machines
refrigerant ng unit contain flooded without flooded dispensing warehouses refrigeration
(New**) (Retrofit***) (Retrofit** (New) (Retrofit** (New)
(New) evap. evap. equipment (New) (New)
*) *)
(New) (New) (New)
R- Jan. 1, July 20, July 20,
Jan. 1, 2017 July 20, 2016 Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 Jan. 1, 2021 ^Jan. 1, 2023 OK OK
404A/507A 2018 2016 2016
R-410A OK - OK - Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 - Jan. 1, 2021 ^Jan. 1, 2023 OK OK
R-407C/F OK
R-407A/C/F OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 Jan. 1, 2020 OK ^Jan. 1, 2021 R-407A: OK R-407C only
^Jan. 1, 2023
HFC-134a OK OK OK OK Jan. 1, 2019 Jan. 1, 2020 OK OK OK OK OK -
Likely alternatives
(Emerson perspective)
Neither SNAP- Neither SNAP-
R- OK for
OK OK OK OK approved, nor approved, nor OK - - OK -
448A/449A banned banned LT only
R-
OK OK OK OK OK OK OK OK OK OK OK -
450A/513A
R-290 - - - - OK OK OK - - - OK OK
R-744 OK - OK - OK OK OK - OK OK - OK
OK OK OK
OK
(In primary OK OK (in primary (in primary OK
(in primary loop
R-717 of secondary
- loop of - (in primary loop of (in primary loop of loop of loop of (in primary loop of OK OK -
secondary secondary system) secondary system) secondary secondary secondary system)
system)
system) system) system)
** 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.
*Abbreviated – For complete listing, see EPA Final Rule; go to: https://www.gpo.gov/fdsys/pkg/FR-2015-07-20/pdf/2015-17066.pdf
See proposed rule; go to: https://www.gpo.gov/fdsys/pkg/FR-2016-04-18/pdf/2016-08163.pdf
4
Energy
EPA Refrig. Environment
Equipment
Compliance Will Not Be Easy DOE Energy Economics
2017 2018 2019 2020 2021
Supermarket (Rack)
OEM Preparedness to Meet Compliance Dates
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.
EPA Plan in Place DOE Plan in Place
Not yet Not yet
Yes 36% Yes
44%
52% 57%
Level of Preparedness: Level of Preparedness:
13% 52% 15% 17% 15% 45% 19% 17%
Equipment Passes EPA Regulations: Equipment Passes DOE Regulations:
48% 74%
(mean)
(mean)
Very prepared Somewhat prepared Only slightly prepared Not at all prepared
6
OEM-Specific Preparations for Meeting DOE Regulations
Communicating plan to …
While 62% Are Lab Testing to Prepare (among those communicating plans to customers)
for DOE Regulations, the Remaining
Two in Five Are Not. End use customers 87%
Many customers are still seeking
guidance on becoming better prepared. Aftermarket/wholesalers/ 47%
distributors
Contractors 20%
DOE preparations Other
13%
We’re lab testing as a way
to prepare. 62%
Seeking guidance from …
We’re seeking guidance on (among those seeking guidance to prepare)
how to be better prepared. 49%
We have a product road Component manufacturers 87%
map. 43%
We’re communicating our
Consultants 35%
plans to customers. 32%
End use customers 22%
Other 13%
Other 9%
7
Agreement With Statements Related to
Regulatory Changes
Top-2 Box
The Majority Expect Components Will Change Based on the Regulations.
This, in Turn, Will Impact Cost Negatively.
Top-2 Box
I expect some components
will change. 77% 12% 10% 2% 89%
I expect some of our products
to become obsolete. 53% 10% 14% 10% 14% 63%
I expect component costs to
increase. 51% 22% 20% 4% 4% 73%
5 = Completely 1 = Completely
4 3 2
Agree Disagree
8
Commercial Refrigeration Equipment
Equipment Classes
Low- or Medium-
Temperature
Vertical, Semi-Vertical,
Horizontal or Service
Over Counter
Equipment Affected
Self-Contained Buffet Tables, Salad Bars, Prep Tables Not Affected
or Remote Condensing Depending Upon Refrigeration Construction
With or Without
Solid/Transparent Doors
Commercial Refrigerator
and Freezer
33+ Classes of Equipment
20+ Sizes/Eqp. Class
Source: Department of Energy
9
Buffet Tables, Salad Bars, Prep Tables Beyond
Scope of Energy Mandates
Regulated Regulated Not Regulated Not Regulated
Top Airflow Airflow
Rail
Bottom
Storage
Source: Department of Energy
1CRE Prep and Buffet Tables
Architectures and Compliance Note
Top Rail Bottom Storage Certification Required Criteria
No Power Supplied or From Common Supply See Refrigeration
Power Supply Single Energy Source
With Top Requirements
Power Supply Power Supply Yes Dual Energy Source With Single Source Requirement
Certification
Top Rail Bottom Storage Criteria
Required
Refrigerated: Cold Dry – Regular Buffet/Prep Construction –
No
Can’t Be Tested
Test Procedure
Wall or Forced Air Non-Refrigerated No Classification
w/DOE
Refrigerated: Air In
Refrigerated: Cold
Lower Section Coming Heat From Upper Rail Is Being Absorbed
Wall or Forced Air
in Direct Contact Directly Into Lower Section Refrigeration
With Heat Being No
With Top Rail and System With Single Energy Source and
Rejected Directly
Single Condensing Single Refrigeration System
Into Lower Section
Unit
Refrigerated: Cold
Refrigerated: Cold
Wall or Forced Air Heat From Upper Rail Is Not Being
Test Procedure
Wall or Forced Air
Can Be Tested
With No Direct Absorbed Directly Into Lower Section
With No Direct Yes
Contact With Rail Refrigeration System With Single Energy
w/DOE
Contact With Lower
Section and Single Source and Single Refrigeration System
Section
Condensing Unit
Refrigerated: Cold Refrigerated: Cold
Dual Refrigeration System With Single
Wall or Forced Air Wall or Forced Air
Yes Refrigeration System Requirement, Single or
With Its Own With Its Own
Dual Energy Source
Condensing Unit Condensing Unit
There Are No Exemptions From the Energy Standard for Commercial Refrigeration Equipment. However, There Are Some Equipment
Types That Do Not Have a Test Procedure and Therefore Do Not Have to be Certified at This Time.
Source: Department of Energy
11CRE Equipment DOE Analysis and Equations
• X-axis: size of equipment ft3 • 33 classes of equipment
• Y-axis: energy draw kWh/day • Remote condensing and self-contained open
• Equation format: Y = m(x) + b cases will not require major efficiency
• kWh = m(ft3) + b improvement challenges
• Self-contained vertical reach-ins will require
significant efficiency improvement changes
Equations y-Intercept Slope
2010 2012 2017 2010 2012 2017 % Delta 2010 2012 2017 % Delta
VOP.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%
Source: Department of Energy
12CRE Equipment DOE Analysis and Equations
70% VCT.SC.M VCT.SC.L VCS.SC.M VCS.SC.L
67%
VCT.SC.M 0.12(V) + 0.75(V) + 0.10(V) + 0.40(V) +
64% 2010 kWh =
3.34 4.10 2.04 1.38
2017 v. 2010 Energy Reduction Difference %
61%
VCT.SC.L 0.10(V) + 0.29(V) + 0.05(V) + 0.22(V) +
58%
2017 kWh =
0.86 2.95 1.36 1.38
55%
Y-intercept
-74% -28% -33% 0%
52% % change
49%
VCS.SC.M Slope
-17% -61% -50% -45%
46% % change
43%
40%
Comparing 2017 vs. 2010
1. Improvement reduces relatively for larger size machines
37%
• VCT.SC.M
34% 2. Improvement increases substantially for larger size machines
31% • VCT.SC.L
VCS.SC.L • VCS.SC.L
28%
3. Improvement levels out for larger machines
25% • VCT.SC.L
• VCS.SC.L
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
5
100
Size ft3 • VCS.SC.M
Source: Department of Energy
Source: Department of Energy
13Walk-in Coolers and Freezers (WICF)
Equipment Classes
• Dedicated Recip. Hermetic, Semi-
– Single walk-in feed Hermetic Recip. or
Scroll Compression
– A packaged dedicated system
Medium- or where the unit cooler and = 9K BTU/h
into a single piece of equipment
– A split dedicated system
with separate unit cooler Indoor or Outdoor
and condensing unit
Multiplex Condensing sections
Medium- or
• Multiplex Low-Temp
– Unit coolers matched to
multiplex condensing rack
Dedicated
system Condensing
Source: Department of Energy
14WICF AWEF Improvement Design Option Costs
Dedicated Condensing MT/LT by BTU/h
Average Costs New Costs for Meeting AWEF
$16,000 $16,000
$3,269 $4,684 +43%
$14,000 $14,000
$12,000 $12,000
$10,000 $10,000
$8,000 $8,000
$6,000 $6,000
$4,000 $4,000
$2,000 $2,000
$0 $0
6000 9000 54000 72000 18000 54000 6000 9000 6000 54000 72000 18000 54000 6000
L M L M
DC DC
I - HER $1,528 $1,648 $2,130 $1,448 I - HER $2,171 $2,370
I - SCR $1,754 $1,873 $6,754 $2,348 $3,575 $6,233 I - SCR $2,365 $2,204 $7,568
I - SEM $1,993 $4,653 $2,588 $4,103 $4,242 I - SEM $2,452 $7,571 $4,387 $4,568
O - HER $1,558 $1,678 $2,160 $1,479 O - HER $2,494
O - SCR $1,785 $1,903 $6,819 $2,379 $3,615 $6,289 O - SCR $9,668 $2,682 $3,978 $7,003
O - SEM $2,024 $2,154 $7,246 $9,133 $2,618 $4,143 $4,286 O - SEM $10,530 $13,706 $4,603 $4,771
Source: Department of Energy
15Automatic Commercial Ice Makers
Overview
• Affecting batch ice machines also known as “cubers”
• Affecting continuous ice machines also known as “flakers” or “nuggets”
Self-contained
Air or water Various harvest
or remote
cooled rates
condensing
• Frozen carbonated beverage machines not affected
Source: Department of Energy
16Polling 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 this
B. Haven’t started engaging the channel on getting prepared
C. Getting prepared to engage the channel now
D. I’m ready and have communicated to all stakeholders in my channel
17Commercial Refrigeration Equipment
Design option vs. cost
CDU
System Compressor
component
$ OEM Cost Adder
$90
Solid-Door Reach-In Refrigerator
$80
(DOE/ADL Study)
VS Compr
vs. comp.
$70
$60
kWh/Day Payback
BetterBetter
Insulation BPM Compr Mtr 2.0 years
BPM motor
$50 insulation
Hot-Gas
Hot gas
Antisweat
anti-sweat
$40
1.0 year
$30
ECM Evap Fan LED
lighting
$20 ECM evaporator /
condenser fan
ECM Cond Fan 0.5 year
High-effy.
Higher Eff
$10 comp.
Compr
kWh/day = comp. energy draw +
lighting + fan + controls + others % Energy Saving
$0
0% 5% 10% 15% 20% 25%
Total System Measurement Based on Equipment Type; CDU Is Treated as Component
Source: Department of Energy
18Reach-ins: Energy Considerations
• 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
19Walk-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
20DOE Design Options to Meet AWEF Summary
Electronically Improved
Floating Head Modulating
Commutated Evaporator Fan
Pressure Evaporator Fans
Motors Blades
Temperature-
Improved
initiated,
Hot Gas Defrost Improved Coil Condenser Fan
Temperature-
Blades
terminated Defrost
Variable Speed Variable Speed Variable Speed Ambient
Compressor Condenser Fans Evaporator Fans Sub-cooling
Source: Department of Energy
21Floating Head Pressure vs. Fixed
Source: Emerson
22Taking Advantage of Low Ambient
Source: Emerson
23Automatic Commercial Ice Makers
Cycle Understanding
Start Batch Continuous Both
• 30/110
• 15% Run Time Ice Machine Improvement Levers
Ice Machine Transient Model
Stabilize
• 15/115
• 70%
Finish
• 0/105
• 10%
Harvest
• 45/95
• 5%
24Measures Being Taken to Increase Energy Efficiency
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.
Walk-ins Reach- Ice/FCB/ Racks
Total ins SS
Switching to more efficient fan
motors 71% 75% 74% 64% 83%
Switching to more efficient
compressors 69% 75% 74% 55% 75%
Using LED lighting 65% 56% 71% 46% 75%
Top energy
efficiency
Using more electronic controls 59% 69% 60% 55% 67%
improvements
Using larger heat exchangers 35% 44% 37% 27% 50% that will
provide the
Switching to electronic
expansion valves 31% 50% 17% 18% 50% best return on
investment
Improving the amount of
insulation 29% 38% 37% 18% 25%
Switching to scroll compressors 26% 50% 20% 9% 17%
Using adaptive electric defrost 26% 56% 20% 0% 50%
Using floating head pressures 18% 44% 14% 9% 33%
25Current Number of Models Listed
CRE ACIM WICF
37,616 797 1,673
• 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
Source: Department of Energy
26Polling Question 2
In 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.
27Thank You!
Questions?
DISCLAIMER
Although 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.You can also read
