Fryer Replacement Field Monitoring Study Report Fisher Nickel Inc. November, 214 Prepared By: Denis Livchak Contributors: Richard Young Prepared For: Anthony Hills Southwest Gas North Las Vegas, NV 893 and Todd Megrath MGM Resorts International Las Vegas, NV 8919 Test Site: Aria Resort & Casino 373 S Las Vegas Blvd Las Vegas, NV 8919 Test Date: June - 214
Study Test Date: June - September, 214 Facility name: Aria Resort & Casino Facility Address: 373 S Las Vegas Blvd Las Vegas, NV 8919 Introduction: The Aria Resort and Casino is a part of the CityCenter complex on the Las Vegas Strip. This 61 story resort has 16 restaurants and 1 bars and nightclubs. Aria Café is the largest 24 hour café on the Las Vegas Strip serving casual dishes in a sophisticated and contemporary setting (Figure 1). Aria Buffet is open for breakfast, lunch and dinner and serves a plethora of fresh dishes spanning several continents. Figure 1. Aria Café Dining Room In its quest to increase cooking production capacity and meet corporate sustainability goals, MGM Resorts is exploring several options to replace their outdated fryers. MGM contacted Southwest Gas which arranged funding for the project through its participation in the Utilization Technology Development, NFP (UTD) with the Gas Technology Institute (GTI). The UTD, a not-for-profit corporation, is directed by participating companies, to manage a gas-focused technology program for the benefit of the investors and their customers. GTI, Southwest Gas collaborated with the Food Service Technology Center for technical support and assistance in analyzing energy usage of existing fryers and quantifying energy savings associated with energy efficient alternatives. The Food Service Technology Center assisted Southwest Gas in selecting metering equipment which was used for monitoring the energy consumption of the three existing double vat fryers at two restaurant locations. After baseline energy monitoring was conducted on the existing fryers, they were replaced by energy efficient fryers of the same size and monitored for several weeks. Hours of operation, usage patterns and daily energy consumption was analyzed. Baseline and replacement data was compared in order to justify future replacement of inefficient fryers at other MGM sites.
Test site: The sites chosen for baseline energy monitoring had the most customers or had the longest hours of operations. Aria Café is a 24/7 restaurant with two double vat fryers that are operated at alternate shifts. Aria Buffet is open from 7AM to 1PM daily and has a steady stream of customers anytime between those hours. Both kitchens require a high volume production fryer to be able to keep up with the customer demand. Aria Café has a large kitchen with several lines high duty cooking appliances. The two double vat fryers were located on the opposite sides of the kitchen hood (Figure 2). The fryers were missing front casters and were leaning forward causing the oil level to be uneven. At the Aria Buffet, the double vat fryer was located in the back of the kitchen (Figure 3). All three gas double vat fryers were the same model and had a maximum input rate of 12 kbtu/h per vat. Each vat was 15" wide and had an oil capacity of 5 lb heated by two atmospheric burners. Each vat had a standing pilot that was operating 24/7 and manual millivolt thermostats. Figure 2. Aria Café Baseline Fryer Figure 3. Aria Buffet Baseline Fryer
Monitoring Equipment and Testing Procedures: Southwest Gas Engineers assembled the data logger enclosure and attached it to the gas meter. The gas meter was then attached to the back panel which contained all the utility connections (Figure 4). The gas meter was then connected inline between the fryer and the gas source. Each double vat fryer had one gas connection and both vats were utilized simultaneously. The gas meter generated a pulse for every cubic foot that was consumed (Figure 5) and pulses were recorded using an Onset HOBO data logger at 3 second intervals. Data was downloaded manually during different periods of monitoring. Figure 4. Gas Meter with Data Logger During baseline monitoring there were some problems with the gas meters due to the cleaning practices of the staff. The plastic gas meter gears fell out of position when the meter was hit during intensive cleaning. Southwest Gas replaced two of the gas meters and reprogrammed the data loggers. The baseline monitoring period at the Aria Café was extended due to these technical difficulties. Initially, it was assumed that the two fryers at Aria Café were used intermittently, however the baseline data suggests otherwise and there were several days when both fryers are operating simultaneously. The first fryer was used 77% of the time and the second fryer is used 73% of the time, not 5/5 as suggested earlier. The overlay when both fryers are operating simultaneously occurred during the weekend days of Friday and Saturday. Initially the energy during off days was attributed to the standing pilot light, however it was discovered that instead of being turned off, the fryer thermostat was set on the minimum setting at Aria Café. Figure 5. Gas Meter Readout
Data and Results Baseline: At Aria Café, the first baseline fryer consumed 12.32 therms per day when it was in use, and 3.8 therms when it was not. During the monitoring period, the fryer was in use 77% of the time. This means the weighted average throughout the week was 1.19 therms per day. A typical on profile is shown in Figure 6 and a typical profile during non-operation days is shown in Figure 7 which shows the low temperature idle between 5AM and 9AM and the pilot energy rate between 1AM and 1PM. 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 6. Aria Café Baseline Fryer 1 Typical On Day 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 7. Aria Café Baseline Fryer 1 Typical Non-Operating Day
At Aria Café, the second baseline fryer consumed 1.62 therms per day when it was in use and 1.9 therms when it was not. During the monitoring period, the fryer operated 73% of the time. This means the weighted average throughout the week was 8.24 therms per day. A typical on profile is shown in Figure 8 and a typical non-operational profile is shown in Figure 9 which shows the low temperature idle. 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 8. Aria Café Baseline Fryer 2 Typical On Day 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 9. Aria Café Baseline Fryer 2 Typical Non-Operating Day
At Aria Buffet, the baseline fryer operated every day and consumed 7.96 therms per day on average. A typical energy usage profile is shown in Figure 1. The pilot rate is shown between 1PM and 4AM. 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 1. Aria Buffet Baseline Fryer Typical Daily Profile Replacement: After baseline monitoring has been completed, three high input rate low efficiency fryers were replaced by top of the line fryers from three major manufacturers. These were the most efficient fryers of equivalent size available on the market by the three selected manufacturers. The replacement fryers featured more efficient gas heat exchanger technologies and power burners compared to the baseline fryers; however the analog controls remained very similar. At Aria Café, the first baseline fryer was replaced with two Frymaster H55 series fryers (Figure 11). The replacement consumed 5.48 therms per day when it was in use and 1.99 therms when it was not. During the monitoring period, the fryer operated 77% of the time. This means the weighted average throughout the day was 5.51 therms per day. A typical on profile is shown in Figure 12 and a typical off profile is shown in Figure 13 low temperature idle. Figure 11. Aria Café Replacement Fryer 1
2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 12. Aria Café Replacement Fryer 1 Typical On Day 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 13. Aria Café Replacement Fryer 1 Typical Non-Operating Day The replacement of the existing baseline double vat fryer at Aria Café with two Frymaster H55 fryers resulted in 54% energy reduction amounting to 5.51 therms per day.
At Aria Café, the second baseline fryer was replaced with two Vulcan 1VK45 series fryers (Figure 14). The replacement consumed 4.2 therms per day when it was in use and.93 therms when it was not. During the monitoring period, the fryer operated 73% of the time. This means the weighted average throughout the day was 3.31 therms per day. A typical on profile is shown in Figure 15 and a typical off profile is shown in Figure 16 which shows that the fryer was completely off after 2AM. Figure 14. Aria Cafe Replacement Fryer 2 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1111213141516171819221222324 Figure 15. Aria Café Replacement Fryer 2 Typical On Day 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1111213141516171819221222324 Figure 16. Aria Café Replacement Fryer 2 Typical Off Day
The energy during off days was significantly lower for the replacement fryer because it had electronic ignition and did not require a standing pilot. The staff kept these fryers completely off compared to leaving them on at a low temperature idles shown with the other fryer at the Aria Café. The energy usage between hours and 2 is carryover energy from the previous on day. The replacement of the existing baseline double vat fryer with two Vulcan 1VK45 fryers resulted in 6% energy reduction amounting to 4.93 therms per day. At Aria Buffet, the baseline fryer was replaced with two Pitco SSH55 series fryers (Figure 17). The replacement fryers operated every day and consumed 3.41 therms per day on average. This fryer had electronic ignition which meant that it did not use any pilot energy. A typical energy usage profile is shown in Figure 18. Figure 17. Aria Buffet Replacement Fryer 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 18. Aria Buffet Replacement Fryer Typical Daily Profile The replacement of the existing baseline double vat fryer with two Pitco SSH55 fryers resulted in 57% energy reduction amounting to 4.55 therms per day.
Conclusion: Baseline fryer replacement with energy efficient fryers resulted in significant energy savings across all three sites. The average savings were 57% or 5 therms per day per site. The table below summarizes the replacement results for all the sites. Table 1. Gas Therm Savings at Each Monitored Location Location Café 1 Café 2 Buffet Pre 1.19 8.24 7.96 Post 4.68 3.31 3.41 Savings 5.51 4.93 4.55 Savings 54% 6% 57% Baseline Replacement 12 Energy Usage (therms/day) 1 8 6 4 2 Café 1 Café 2 Buffet Figure 19. Aria Replacement Fryer Energy Savings The significant fryer energy savings were attributed to much more efficient heat exchangers, power burners and electronic ignition in replacement fryers. Figure 2 shows an overlay of the baseline and replacement energy profiles for the same location. Pilot energy is eliminated and the replacement fryer is idling at a much lower input rate while maintaining the same temperature and improving production capacity through faster recovery times.
Baseline Replacment 24 22 2 18 16 14 12 1 8 6 4 2 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 2. Baseline vs Replacement Fryer Energy Profiles. It was initially though that the baseline fryer at Aria Café had a very high pilot rate accounting for almost 3 therms during off days. This suggests that the pilot rate was above 1 kbtu/h (Figure 21). Once the replacement fryer with electronic ignition was installed, the same pattern emerged, although this perceived pilot rate was lower at 2 therms per day. This meant that instead of turning the fryer off during off days, the operator would simply turn down the thermostat on the minimum setting instead of turning off the fryer completely. This observation is highlighted by the preheat spike preceding the low temperature idle. Figure 22 illustrates this on the replacement fryer, where it was truly off between and 6 am, then preheated at 7 am. Between 7 am and 11 pm the fryer was idling at a low rate indicating that the thermostat was set very low, however no cooking was taken place because it is a steady idle. At 11pm the fryer was preheated to cooking temperature.
12 1 Low Temp Preheat 8 6 4 2 Fryer Off Fryer Thermostat Turned Down, No Cooking 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 21. Fryer Thermostat Reduction Instead of Turning it Off Baseline Fryer 12 1 8 6 4 2 Fryer Off Low Temp Preheat High Temp Preheat Fryer Thermostat Turned Down, No Cooking 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 2 21 22 23 24 Figure 22. Fryer Thermostat Reduction Instead of Turning it Off Replacement Fryer Instructing the staff to turn off the fryer instead of turning down the thermostat during the off days can save 2 therms per day even with the replacement fryers.
Appendix: Baseline Fryer for all Three Sites:
Appendix: Baseline Fryer for all Three Sites:
Appendix: Aria Café Replacement Fryer 1 Spec Sheet:
Appendix: Aria Café Replacement Fryer 1 Spec Sheet:
Appendix: Aria Café Replacement Fryer 2 Spec Sheet:
Appendix: Aria Café Replacement Fryer 2 Spec Sheet:
Appendix: Aria Buffet Replacement Fryer Spec Sheet:
Appendix: Aria Buffet Replacement Fryer Spec Sheet: