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COOLING CONTROL IN
MANUFACTURING
Dan Mascola
AGENDA
• Promote
• Background
• Understanding Your Facility
• Cooling Control Solutions
– Case Studies
• How To Start on Monday
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PROMOTE
PROMOTE
Thanks electric company!
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PROMOTE
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PROMOTE
• Monthly newsletter or email
– Daily facility energy use
– Greenhouse gas emissions...# of cars
– Active energy projects
– Tips tenants can do to reduce energy use
• Posters
• Quarterly events
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BACKGROUND
PERSONAL BACKGROUND
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• Product Marketing Manager at Vigilent®
• Energy analysis
– Lighting, chillers, boilers, pumps, economizers, ventilation, process
• Building audits and walkthroughs
– Commercial, campus, labs, data centers, manufacturing, industrial
• Program management
– LEED, utility incentives, M&V, RCx, product development
www.dchuddle.com
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ABOUT VIGILENT
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• Provides intelligent energy management systems for data centers, telco, central offices and buildings
– Intelligent control – dynamic, predictive, adaptive
– Rapid deployment with minimal incursion
– Instant savings on energy costs
– Uniquely informed by Big Data, directed by Big Analytics
UNDERSTANDING YOUR FACILITY
TYPES OF MANUFACTURING FACILITIES
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
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TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
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TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
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TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
TYPES OF LOADS
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
OFFICE BUILDING
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• Be comfortable
• Individual Control
• Occupied/Unoccupied
Resulting HVAC System
• Complex
• Serve diff. zones
• Dynamic control
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WAREHOUSE
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• Be boxes
• Large area to store
and move things
Resulting HVAC System
• Non existent?
• Heating in cold climates
• Minimize infiltration
COLD STORAGE
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• Temperature limits
• Requires 24/7
conditioning
• Stored and moved Resulting HVAC System
• Special cooling equipment
• 24/7 operation
• Not dynamic
DATA CENTERS
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• Temperature limits
• Requires 24/7 conditioning
• Mission critical
Resulting HVAC System
• Dynamic cooling control
• Super redundant
• 24/7 operation
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PARKING GARAGES
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• Potentially harmful emissions
• Dynamic
Resulting HVAC System
• Ventilation heavy
• Dynamic control
• Conditioning not required
ARENAS AND STADIUMS
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• High density of people
• Large Open Space
• Periodic
Resulting HVAC System
• Cooling only
• Large ventilation capacity
• Periodic use requires dynamic control
HOSPITALS AND LABS
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• Health requirements
• 24/7 operation
• Mission critical
Resulting HVAC System
• Ventilation heavy
• Airflow sensitive
• 24/7 operation
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PROCESSING PLANTS
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People
Boxes
Frozen Food
IT Equipment
Cars
People
Sick People
Almost Anything
• Production lines
• Manufacturing
• Waste Water Treatment
Resulting HVAC System
• Facility specific
• Elec. Motors dominate energy use
TYPES OF FACILITIES
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• Office Building
• Warehouse
• Cold Storage
• Data Center
• Parking Garage
• Arenas/Stadiums
• Hospital and Labs
• Processing Plant
Require Cooling
Control Solution
COOLING CONTROL SOLUTIONS
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Data Centers
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DATA CENTERS
• Energy is single largest operating expense
– Overcooled, but IT loads increasing
• 42% of data centers will run out of power,
cooling, or space in the next two years
• Technical Issues
– Existing controls non existent, all on all the time
– No visibility into inlet temperatures
– Manual control is time consuming, error prone
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DATA CENTERS
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DATA CENTERS
• Monitor inlet
temperatures
• Allocate cooling
resources
• Dynamically manage
cooling units
• Optimize temperature
distribution
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Typically results in 40%
cooling energy savings
DATA CENTERS
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MEASURE • Instrument the environment
MODEL • Profile the dynamic system
• Simulate effect of changes
MANAGE • Optimize closed-loop control
• Modify infrastructure
DATA CENTERS
CRIME OF ENERGY MANAGEMENT | 36
Site Name
Square
Feet Sensors CRAHs
kWh
Savings
Dollar
Savings
Cooling
Reduced
Office of Technology Services, Gold Camp 40,000 495 23 484,174 $48,417 19%
Employment Development Department 12,500 63 5 433,049 $43,305 54%
Franchise Tax Board LA Data Center 12,000 126 15 697,045 $69,705 78%
Department of Water Resources 5,300 53 6 288,348 $28,835 40%
Department of Trans. (Caltrans), 2nd Floor 4,000 44 4 149,555 $17,947 64%
Secretary of State 2,700 32 5 37,084 $3,708 30%
Department of General Services, Ziggurat 2,500 41 4 84,134 $11,358 50%
Department of Trans. (Caltrans), 9th Floor 667 31 3 140,135 $16,816 64%
Totals 79,667 885 65 2,313,524 $240,091 41%
8 State of California Data Center Results
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DATA CENTERS
• Reduced energy consumption of eight data centers by more than 2.3 million kWh
• Projecting over $240,000 in annual savings
• Results achieved at diverse set of data centers
– Demonstrates the power and flexibility of intelligent energy management
• Works in big or small, old or new data centers
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8 State of California Data Center Results
Arenas and Stadiums
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ARENAS AND STADIUMS
• Way overprovisioned
– Designed for fully occupied on hottest day of
the year….+30% more
• Extremely dynamic environment
– Basketball practice vs basketball game
• Single large open space makes monitoring
easy and control simple
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ARENAS AND STADIUMS
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“One second ROI”
ARENAS AND STADIUMS
• 23 wireless temperature sensors
• 1 gateway to collect temperature information
• 1 server that operates intelligent control
• 4 wireless control modules for VFD
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ARENAS AND STADIUMS
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Processing and Manufacturing
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PROCESSING PLANTS
• Previous experience
– Waste water, dairy, recycling, waste
management, cold storage, iron ore processing
plant, mill/lathe manufacturing plant
• Electric motors consume the most energy
• Significant heating costs for sites in cold
climates
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PROCESSING PLANTS
• Motor opportunity for savings
– Turn off production lines (motors) when not in
use
• Use sensors to cycle equipment on/off
– Replace old motors with high efficiency,
especially if they operate 24/7
– Consider VFDs if motors do not need to
operate at 100% all the time
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PROCESSING PLANTS
• Equipment replacement opportunities
– Replace old antiquated equipment with newer
more efficient equipment
– Buy equipment that can streamline process or
operation
• ActOnEnergy may be able to provide incentives
based on incremental energy savings when
selecting premium efficiency equipment over
standard equipment
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PROCESSING PLANTS
• Heating savings opportunities
– Electric heating = BAD
• Expensive and increased demand charges
– Improving insulation is the lowest hanging fruit
• Add air curtains loading docks
• Repair holes metal siding, roof
• Add insulation where possible
– Turn it off when you are not using it
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HOW TO START NEXT MONDAY
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WHAT TO DO NEXT MONDAY
• Measure energy from top down
– Facility Energy: electric bills, borrow monitoring
equipment, ask utility for data
– End Use Energy: lighting, processing rooms, IT
equipment
– Equipment Energy: Individual cooling units,
single production line, single piece of equipment
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NEXT STEPS
• Graph to identify patterns
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vs
NEXT STEPS
• Ask questions and point to areas for potential
improvements
– “Maybe our fans don’t need to run at 100%
during this event”
– “Why are we heating overnight?”
– “Why does this production line use more energy
than this one?”
CRIME OF ENERGY MANAGEMENT | 51
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NEXT STEPS
• Find solutions to achieve goals
– Install intelligent cooling control for data centers
– Implement wireless monitoring and control for
AHUs in arena or stadium
– Control production lines based on sensors or a
time schedule instead of running 24/7
– Your utility is out to help, ask about incentive
programs
CRIME OF ENERGY MANAGEMENT | 52
ACTONENERGY INCENTIVES
• Available cash incentives (based on annual
energy savings)
– Electric Savings
• Lighting $0.06/kWh
• HVAC $0.08/kWh
– Gas Savings
• All $1.20/therm
CRIME OF ENERGY MANAGEMENT | 53
NEXT STEPS
• Don’t forget to promote!
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QUESTIONS
Questions?
CRIME OF ENERGY MANAGEMENT | 55
Dan Mascola
Blog: www.dchuddle.com
Twitter: @dchuddle