Energy Code and Fan Efficiency: How ASHRAE 90.1 and IECC Codes Changed Fan System Design for Healthcare & Institutional Facilities

Energy Code and Fan Efficiency: How ASHRAE 90.1 and IECC Codes Changed Fan System Design for Healthcare & Institutional Facilities Scott Sevigny, PE Shah Smith & Associates Mike Donovan HTS Texas

Agenda ØBackground & History-> Fan Systems ØFan System Efficiency ØHow the Industry Arrived at FEG? ØWhat the Codes & Standards State ØSystem Design Practices What can we do? ØEnergy Code Compliance and Application ØExamples of Fan System Analysis with FEG ØWhat s Next for code and standards development

Fan Systems are a big part of Building energy consumption 2.5 QUADS is 450 million barrels of oil or 95M tons of Coal annually Fans 38% Chiller 34% Pumps 23% Tower 5% Annual Energy Usage 60% of energy is moving or transporting BTU around buildings

The Last 20 Years? 95+ DBA 100+ DBA 91+ DBA 88+ DBA 80+ DBA 88+ DBA 55% Efficiency (FC Fan*) 78% Efficiency (AF Fan*) *Includes 7% loss for V-belt drive 78% Efficiency (PLENUM FAN) Reliability Improved at the same time 70% Efficiency (Fan Array) BELTS & Sheaves + I bearing 84% Efficiency (Flow Enhancement) ALL IN + motor, vfd, bearing, motor fraction 75% Efficiency (Brushless DC motor) ALL IN

AMCA 2010 Tells us smaller diameter fan wheel/impeller is less efficient than larger diameter fan wheel/impeller 90 85 80 75 70 65 60 55 50 EFFICIENCY 0 10 20 30 40 50 60 EFFICIENCY

NEMA MG.1-2016 tells us smaller motors are less efficient than larger motors Great Reference Document: https://www.energy.gov/sites/prod/files/2014/0 4/f15/amo_motors_handbook_web.pdf

What is the consumer paying in electricity and what is involved? AHRI 1210 AMCA 210 4-5% 2% 15-40% 5-9% 5-12% POWER IN VFD loss (4-5%) Motor Loss (5-12%) Belt Loss (5-9%) Bearing Loss (2-3%) Fan Aero Loss Power Out 15-40% NEMA MG.1 Input Power AMCA 203 ALL-IN!

Industry Yesterday 1917 NAFM (National Association of Fan Manufacturers)-standard 110 which became AMCA standard 210 1923 Fan Testing for the US Navy Origin of AMCA 210 1955 AMCA formed (Air Movement and Conditioning Association) 1960 AMCA Standard 210 1970 AMCA (Air Movement and Control Association) ~1985 AMCA 301, 311 research of fan sound

DOE NOT HAPPY WITH PROGRESS BY OUR INDUSTRY (CIRCA 2007) In 2005-2006 Various Standard Organizations (DOE, ASHRAE, AMCA) Began Looking For a Better Means to Reduce Energy Consumption By Building Fans Regulators (DOE) mount up

2007 Fan Efficiency Grade (FEG) Committee is Born ü Simple System to indicate the aerodynamic quality of a fan. ü Based on Fan s Peak total efficiency ü FEG is calculated using airflow, pressure, input power. ü Does NOT account for drive and motor efficiency

Adoption Of Fan Efficiency Grades 2007 - Fan Efficiency Grade (FEG) Committee is Born 2010 - AMCA 205-Energy Efficiency Classification for Fans Published 2012 AMCA 205 updated and Certified by ANSI 2013 ANSI/ASHRAE/IES Std 90.1-2013 Published with AMCA 205 2015 International Energy Conservation Code (IECC) Published 2016 Tx State Energy Conservation Office (SECO) Adopts: ASHRAE 90.1-2013/2015 IECC

ANSI/ASHRAE/IES Std 90.1-2013 Chapter 6 Fan System Power and Efficiency This allows Three Paths for energy Compliance

ANSI/ASHRAE/IES Std 90.1-2013 Chapter 6 Fan System Power and Efficiency This allows Three Paths for energy Compliance 1. Simplified Approach applies only to facilities less than 25,000sqft 2. Prescriptive Path 3. Energy Cost Budget

ANSI/ASHRAE/IES Std 90.1-2013 Chapter 6 Fan System Power and Efficiency This allows Three Paths for energy Compliance 1. Simplified Approach applies only to facilities less than 25,000sqft 2. Prescriptive Path 3. Energy Cost Budget 90.1-2013

ANSI/ASHRAE/IES Std 90.1-2013 Chapter 6 Fan System Power and Efficiency ü FEG Not Applicable ü Full Energy Model REQUIRED ü Goal: balance overall Energy use Ø Ø Ø Ø Ø Envelope, HVAC, Lighting, Misc Power Infrastructure, Domestic Water Heating. ü Economic($$) Comparison: Design to be lower cost than Prescriptive Bldg

2015 International Energy Code (IECC) what do we do? 3 Choices 1. Comply with ANSI/ASHRAE/IES Std 90.1-2013

2015 International Energy Code (IECC) what do we do? 3 Choices 1. Comply with ANSI/ASHRAE/IES Std 90.1-2013 2. Comply with Mandatory/Prescriptive Requirements

2015 International Energy Code (IECC) what do we do? 3 Choices 1. Comply with ANSI/ASHRAE/IES Std 90.1-2013 2. Comply with Mandatory/Prescriptive Requirements 3. Comply with Mandatory Requirements and be 85% or less than energy cost Resulting from Option 2.

2015 International Energy Code (IECC) what do we do? 3 Choices 1. Comply with ANSI/ASHRAE/IES Std 90.1-2013 2. Comply with Mandatory/Prescriptive Requirements 3. Comply with Mandatory Requirements and be 85% or less than energy cost Resulting from Option 2. Choices 2 and 3 require Compliance with FEG

2015 IECC and ANSI/ASHRAE/IES Std 90.1-2013 SECO mandates IECC compliance statewide for all jurisdictions, NOT just state funded buildings as of 2016

2015 IECC and ANSI/ASHRAE/IES Std 90.1-2013 SECO mandates IECC compliance statewide for all jurisdictions, NOT just state funded buildings as of 2016 Conclusion Texas State Law says we need to pay attention to FEG OR do an energy model

Engineering Design Approach Minimize Fan Pressure 1. Size duct conservatively 2. Return Air Path 3. Low face velocity Air Handling units at coils, filters (350-420 FPM) Select efficient fans 1. Trend towards plenum fans for flexibility of discharge and shorter air handler lengths 2. Direct Drive (Beware of 1200RPM Motor Selections!) 3. Fan Arrays (Reliability vs Redundancy) 4. Larger diameter wheels turning slower Mechanical Rooms larger, But Energy Bills SMALLER

Engineering Design Approach 1. Once the design is somewhat set. Go back and check your energy code compliance 2. AT SSA, we calculate bhp/cfm via spreadsheets

BHP(Brake Horsepower) /CFM(Cubic Feet Per Minute) Example STEM Building

Engineering Design Approach 1. Once the design is somewhat set. Go back and check your energy code compliance 2. AT SSA, we calculate bhp/cfm via spreadsheets a. Use the various allowance for pressure drop that is included in the standard

ANSI/ASHRAE/IES Std 90.1-2013 Chapter 6 Fan System Power and Efficiency

Engineering Design Approach 1. Once the design is somewhat set. Go back and check your energy code compliance 2. AT SSA, we calculate bhp/cfm via spreadsheets a. Use the various allowance for pressure drop that is included in the standard b. Check for FEG compliance if using the prescriptive path with equipment selections

Fan Manufacturer Sample Selection Software

1. Don t Forget your Submittal - follow thru and watch what the contractor proposes to buy 2. Check the fans for certification in the field. The fans shall bear both the following labels: Engineering Design Approach

Is Fan Efficiency Grade (FEG) the bulletproof Answer?

ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67* Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 6 in-wg (1.5 kpa) Selection Efficiency: 80% FEG: 85 Fan diameter: 30 (DWDI-AF) BHP: 24.2 hp (18.1 kw) SFP: 1.2 hp/kcfm FEG: 85 PASS Flow: 20,000 cfm (9.4 m3/s) Pressure: 4 in-wg (1.0 kpa) Selection Efficiency: 58% FEG: 63 Fan diameter: 27 (DWDI-FC) BHP: 22.1 hp (16.5 kw) SFP: 1.1 hp/kcfm X FEG: 63 FAIL ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 6 in-wg (1.5 kpa) Selection Efficiency: 72% FEG: 85 Fan diameter: 24.5 (DWDI-AF) BHP: 27.0 hp (20.1 kw) X SFP: 1.35 hp/kcfm FEG: 85 FAIL Flow: 20,000 cfm (9.4 m3/s) Pressure: 8 in-wg (2.0 kpa) Selection Efficiency: 82% FEG: 85 Fan diameter: 27 (DWDI-AF) BHP: 32.6 hp (24.3 kw) X SFP: 1.76 hp/kcfm FEG: 85 FAIL

ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 6 in-wg (1.5 kpa) Selection Efficiency: 72% FEG: 85 Fan Diameter: 24.5 (DWDI-AF) BHP: 27.0 hp (20.1 kw) X SFP: 1.35 hp/kcfm FEG: 85 FAIL

ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67* Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 6 in-wg (1.5 kpa) Selection Efficiency: 80% FEG: 85 Fan Diameter: 30 (DWDI-AF) BHP: 24.2 hp (18.1 kw) SFP: 1.2 hp/kcfm FEG: 85 PASS ANSWER: Larger Diameter Fan Wheel

Cost of 1.0 BHP (Direct Drive) Cost of Energy = $0.10/kwh 5HP Motor Efficiency = 89.5% 5HP Motors (cost of 1.0 BHP) 24/7 Operation: 50hrs/week: $770 per year $302 per year Quantify in Sq. Ft. 20,000 CFM,6 W.G. 94% motor efficiency FC Fan @ 58% Efficiency = 34.58 bhp (1.85 BHP per 1000 sq. ft. Hospital) AF Fan @ 80% Efficiency 22.88 bhp (1.2 BHP per 1000 sq.ft. Hospital) Difference = 11.6 bhp (single fan)

ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 4 in-wg (1.5 kpa) Selection Efficiency: 58% FEG: 63 Fan Diameter: 27 (DWDI-FC) BHP: 22.1 hp (16.5 kw) SFP: 1.1 hp/kcfm X FEG: 63 FAIL

ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 4 in-wg (1.5 kpa) Selection Efficiency: 67% FEG: 80 Fan Diameter: 24.5 (DWDI-AF) BHP: 21.1 hp (16.1 kw) SFP: 1.05 hp/kcfm FEG: 80 PASS *Changed to AF fan from FC Keep Duct System utilizing Velocity Pressure the same

ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 8 in-wg (2.0 kpa) Selection Efficiency: 82% FEG: 85 Fan diameter: 44.5 BHP: 30.7 hp (22.9 kw) X SFP: 1.53 hp/kcfm FEG: 85 FAIL

ANSI/ASHRAE/IES Std 90.1-2013 Chapter 6 Fan System Power and Efficiency Using the values from the table A = Sum of [PD x CFM / 4131] A = 10.4 bhp (cfm x 0.0013) + A» Up to 36.4 bhp allowed

ASHRAE 90.1 2010: Fan Power Limitation Proposed addition of fan efficiency requirement FEG67 Example (Single fan, VAV, Option 2 = 1.3 hp/kcfm, A=0): Flow: 20,000 cfm (9.4 m3/s) Pressure: 8 in-wg (2.0 kpa) Selection Efficiency: 82% FEG: 85 Fan diameter: 44.5 BHP: 30.7 hp (22.9 kw) SFP: 1.53 hp/kcfm FEG: 85 PASS *PER the 90.1 tables, up to 36.4 bhp allowed or 1.82 hp/kcfm

Industry Today (DOE push) 2010 - AMCA 205 Fan Efficiency Grade Focus on aerodynamic quality of fan based on peak total efficiency Just fan. 2013 - ISO 12759 (FMEG (Fan/Motor efficiency Grade) *2017 - AMCA 207 Fan System Efficiency (NEW) *2018 AMCA 208 Calculation of Fan Energy Index (replaces AMCA 205) NEMA MG.1 Premium Efficiency Motor Tables AMCA 205 has been adopted in IECC-2015, ASHRAE 90.1-2013, 189.1-12, IGCC 2012, IAMPO (Uniform Mechanical Code), and others. Please note that ASHRAE 90.1 2007 first starting using FAN BHP per CFM limitations on full fan systems!

Where are we going? übefore 2010 -> Wild West ü2010 to 2017 -> First Attempt to marry Fan Performance to Fan System Performance. What ultimately is consumer getting? FEG failed to represent the entire picture. Committees starting meeting in 2013 to develop next standards. ü2018 -> Second Attempt. Fan Energy Index (FEI), Fan Electrical Power (FEP) Introduction to WATTS / CFM (similar to chiller KW/TON)

What is the consumer paying in electricity and what is involved? AHRI 1210 AMCA 210 Remember me? 4-5% 2% 15-40% 5-9% 5-12% POWER IN VFD loss (4-5%) Motor Loss (5-12%) Belt Loss (5-9%) Bearing Loss (2-3%) Fan Aero Loss Power Out 15-40% NEMA MG.1 Input Power AMCA 203 ALL-IN!

AMCA 207-17 Calculate Overall Fan System Efficiency (h es ) h es = h S x h B x h MC Fan - h S Belt / Transmission* - h B Motor - h M Drive *For Direct Drive system, h B = 1 Motor & Drive - h MC

AMCA 208-18 Calculation of the Fan Energy Index Utilizing a multi-fan array Ns, ref = 59-60% Best Worst

AMCA 208-18 Calculation of the Fan Energy Index incorrect method Example is for system with 50,000 cfm and fan static pressure of 6. FEP ref = each fan is treated as a single entity in the airstream Highest FEI has highest input power. Best Worst

AMCA 208-18 Calculation of the Fan Energy Index Using Real Data! Fan Type Fan Size Airflow (cfm)/fan Static Pressure FEP ref /n (kw) h s actual h trans def h mtr def h vfd def FEP act (kw) FEI Watts/ CFM EPFN 54.2 50,000 6 66.7 79.92% 100% 95% 96% 46.45 1.44 0.93 85 FEG EPFN (2) 40.2 25,000 6 66.7 80.23% 100% 94.1% 96% 46.27 1.44 0.925 85 EPFN (4) 27 12,500 6 66.7 78.31% 100% 93% 96% 47.40 1.41 0.95 80 ACF (5) 27 10,000 6 66.7 82.0% 100% 93% 96% 44.17 1.51 0.88 85 EPFN (10) 24.5 5,000 6 66.7 77.87% 100% 91.0 96% 47.67 1.40 0.96 85 ECM Array (12) 17.7 4,166 6 66.7 64.9% N/A N/A N/A 51.7 1.29 1.03 90 EPFN (20) 15.0 2,500 6 66.67 65.98% 100% 89.5% 96% 56.03 1.19 1.12 80 h trans = 1 for direct drive system ECM fan efficiency includes motor/vfd losses. Best Worst

Fan Type # Fans CFM/Fan Fan RPM BHP Static Effic. Fan Comparison for Houston Area Hospital Motor Effic. Motor Size Total Effic Total BHP Total Unit kw Total Unit HP W/ CFM Annual Operating cost EPQN365 4 16250 1750 41.24 72.9 93.0 50 67.9 164.9 132.3 200 2.03 $139,095 75 AFLO-27 6 10833 2273 27.9 72.8 92.4 30 67.3 167.4 134.97 180 2.07 $141,881 75 Aero-EP18 12 5417 3440 14.0 70.0 89.5 15 62.7 168 139.95 180 2.15 $147,121 75 EPQN182 12 5417 3500 14.93 67.0 89.5 15 59.9 179.2 149.3 180 2.30 $156,980 75 MPQN182 12 5417 3335 15.31 65.7 90.2 20 59.2 183.7 151.9 240 2.34 $159,725 71 FWT-14 24 2708 3896 8.67 61.0 87.5 10 56.8 207.87 179.14 240 2.76 $188,110 71 FEG * Houston Hospital Texas Medical Center 65,000 CFM at 11.75 TSP, @.105/KWH (FUTURE) Fan Efficiency = (CFM * Pressure)/ BHP (Brake Horsepower) VFD losses not accounted for Best Worst

Watts/CFM for Air Handling Units (KW/TON for chillers) FEI (Fan Energy Index) is a metric to compare Fan System Options FEP (Fan Electrical Power) is the culmination of what the consumer expects to pay for electricity/utility consumption Watts/CFM is a simple metric to relate common language based on the already existing 40 year conversation regarding KW/TON on chillers Fans 38% Chiller 34% Pumps 23% Annual Energy Usage 65% of energy is moving heating/cooling around the building Tower 5%

Questions? Scott Sevigny, PE Shah Smith & Associates Mike Donovan HTS Texas