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Technology Transition

Energy Technologies


Paul Kistler PE CEMU.S. Naval Facilities Engineering and Expeditionary

Warfare CenterAugust 13, 2015

Energy Exchange: Federal Sustainability for the Next Decade

Navy Techval Purpose

•First funded in FY 2004 with O&M funds•Save the Navy money on it’s energy bill through early adoption of new technologies.

– Identify– Validate– Transition

•Meet energy reduction mandates.•Reduce dependence on congressional adds and allow for greater flexibility•Identifies technologies that do not work as advertised.•Technical assistance to rest of Navy.



Techniques and Strategies for Marketing New TechnologiesIdentify and Influence the Decision Makers


• Government• Contractor

•Presentations at conferences•Training classes•Tech Data Sheets•Newsletters•Identify projects performed by others and issue short synopsis•Produce videos of projects•Develop technology discussion forum•Develop partnerships with Universities•Webinars•YouTube videos•Facebook•Web pages


Magnetic Bearing Chiller Compressor

• Attended manufacturer presentation at NAVSEA July 2003• Selected for demonstration August 2003• Selected 1st two sites Newport, RI and San Diego, CA January 2004

– Newport was new chiller– San Diego was a retrofit

• Started up Newport May 2004• Started up San Diego June 2004• January 2006 it was decided to do an additional site at JAX to do hot humid

climate and to install condensing water reset. (retrofit)• San Diego data run completed August 2006• Started transitioning technology August 2006• Newport data run completed September 2006• JAX commissioned and data collection started January 2007• JAX data collection completed January 2008



Location Capacity (Tons) Installation TypeSPAWARSYSCEN San Diego, Calif. 1,200 NCMCRD Parris Island, S.C. 590 NC

60 NC*FRCSW, San Diego, Calif. 180 CR

480 NCNB San Diego, Calif. 440 CR

200 NCPSNS North Island Depot 225 CR

250 NC225 NC*

NB Coronado, Calif. 380 CR*155 NC

NSWC Panama City, Fla. 430 CRNMC San Diego, Calif. 300 CR

100 CR*NSWC Port Hueneme, Calif. 300 NCNAS Key West, Fla. 300 NCMCB Camp Pendleton, Calif. 255 NCNUWC Newport, R.I. 220 NCNAS Lemoore, Calif. 200 NCMCAS Miramar, Calif. 180 NCNAWS China Lake, Calif. 180 NCNAS Jacksonville, Fla. 180 CRMCAS Yuma, Ariz. 125 NCTotal 7,155NC = New Chillers CR = Compressor Retrofits *air-cooled

New Technology Leaders: Oil-free variable speed magnetic bearing chiller compressors installed or in the process of being installed in the DON



How was the Navy able to transition the magnetic bearing chiller compressor

first?



Guide Specs

NAVFAC Design Build Model Request for Proposal – Standard Template

Part 3, Section 6, D303001 Chilled Water Systems:

Provide [[centrifugal] [rotary screw] water-cooled] [[reciprocating] [rotary screw] [scroll] air-cooled] chiller[s] using a [variable

primary] [primary/secondary] [variable speed] pumping system [and [cooling tower] [closed circuit cooler]. [Provide chillers with oil-free compressors including magnetic non-contact compressor

shaft bearings and integral electronic compressor speed control for matching dynamic load conditions].



(As of 2011)UFGS Section 23 64 10, Water Chillers Vapor Compression Type

PART 2 COMPONENTS2.6 CHILLER COMPONENTS

2.6.5 COMPRESSOR(s)2.6.5.4 Centrifugal Compressor(s):

a. Shaft main bearings that are the rolling element type in accordance with ABMA 9 or ABMA 11, journal type with bronze or babbitt liners, or of the aluminum-alloy one-piece insert type. Bearings shall be rated for an L(10) life of not less than 200,000 hours.

c. Lubrication system of the forced-feed type that provides oil at the proper pressure to all parts requiring lubrication.



UFGS Section 23 64 10, Water Chillers Vapor Compression Type

PART 2 COMPONENTS2.6 CHILLER COMPONENTS

2.6.5 COMPRESSOR(s)2.6.5.4 Centrifugal Compressor(s):

d. Provisions to ensure proper lubrication of bearings and shaft seals prior to starting and upon stopping with or without electric power supply. On units providing forced-feed lubrication prior to starting, a differential oil pressure cutout interlocked with the compressor starting equipment shall allow the compressor to operate only when the required oil pressure is provided to the bearings.



How the equipment is spec'd will depend on the PWD, the experience of the staff, the scope of the project, and the acquisition strategy for the project. For smaller, or more familiar projects the spec writers in the FEAD will write the specs in the RFP for you. If that capability is not at the PWD or if the design is too complex then they reach back to the IPT/Core who can either do it in house or use a A/E to assist.

-Navy Energy Manager

I've asked the same questions and have found that it is complex and there are a multitude of variables that come into play. Complexity of work, cost, contract type, timeframe, and ultimately the decisions made by the project manager all play into what specs (if any) are referenced. Based on the answers that I received, I imagine that the requirements and process could actually differ depending on the location.

-Another Navy Energy Manager

Generally the Contractor specifies it although sometimes the Gov't. makes recommendations.-Navy Project Facilitator

In an ESPC, at least in the old process, the spec requirements goes into the DORFP (delivery order request for proposal) and isn't finalized until near the end of Detailed Energy Survey step. Since it is generally up to the ESCO to come up with the technology to propose, specs requirements don't play as large of a role unless there are special requirements.

-Former Navy ESPC program engineer



• 80% to 90% of the building stock that will exist 20 to 30 years from now is already here

• If DoD is going to meet energy goals in the next 20 to 30 years, the existing building stock needs to be addressed (retrofits using newer technologies)

• Navy retrofits do not generally use existing guide specs and criteria

• Guide specs and criteria do not point an energy manager towards the most efficient technology

• If the Navy is going to continue to meet it’s energy reduction goals, it needs to find ways to transition technologies in addition to changing guide specs and criteria.

• In the Navy, purchase decisions are made at the local level so in order to transition technologies, you need to get to the local decision makers and convince them that this is a good technology that will reduce energy use without any negative issues.



From 2006 to 2010 Techval made technical presentations on magnetic bearing chiller compressors to:



Would love to have you come give the presentation you gave at the Fall FUPWG meeting or an updated version of it. NAVFAC SE is very active with energy projects right now and you would be a big draw. Just sending my Navy energy managers a copy of your FUPWG presentation on the Turbocor chillers has prompted our bases to begin installing them.

-Energy Services ManagerPower Company



Drawing courtesy of Danfoss Turbocor Compressors, Inc.

The Magnetic Bearing Chiller Compressor at a Glance



2 ea. 60 ton chiller compressors with magnetic bearingsNAS Jacksonville FL



Compressor Efficacy

Plant Efficacy

Average Load

Average Compressor Power

Cooling Tower Power

Plant Power

New .57 kW/ton .61 kW/ton

75.4 ton 45.9kW 2.44kW 48.3 kW

Existing 1.02 kW/ton 1.04 kW/ton

76.7 ton 78.5kW 1.55kW 80.1 kW

JAX Data



Cost for installation in Jacksonville

Mechanical Subcontractor (including compressor) $95,150DDC Subcontractor $12,442Total $107,592



The Table below presents a synopsis of the data collected for these three projects:

Project Site

Project Type

$/KWH Tons Annual kWh

savings

Annual Energy $ Savings

% Savings

Cost $/Ton Payback (years)

San Diego2006

Add 3rd compressor

$0.121 240 176,717 $21,206 40% $178,787 $744 8.4

NewportSep/Nov

2005

New Chiller $0.115 80 227,760 $26,192 65% $100,783 $1260 3.8

JAXDec/Apr

2006/2007

Compressor Retrofit with Cond. Water

reset

$0.054 120 284,407 $15,358 41% $107,592 $897 7.0



The Table below is the simple payback using the incremental cost:

Project Site Tons Annual Energy $ Savings

Incremental Cost

Payback (years)

San Diego2006

240 $21,206 $24,000 1.1

NewportSep/Nov

2005

80 $26,192 $8,000 0.3

JAX2006/2007

120 $15,358 $12,000 0.8



Maintenance

1. Quarterly tightening of terminal screws 2 work-hours per service (could be done in conjunction with #2 once per year)

2. Annual blowing dust off circuit boards 2 work-hours per service

3. Change capacitors every five years 8 work-hours per service plus $250 for

capacitors

Over 10 years that would be 96 work-hours plus $500 for capacitors.



Other advantages of the compressor

•Quiet – In San Diego the chilled water pumps make more noise than the chiller. Could be a plus if installation is in an area where noise is an issue.

•Light weight – If compressor needs to be changed out, can be accomplished manually by two persons.

•Low startup draw – about 2 amps. Could be a plus if you are replacing or installing a backup generator since generator can be downsized to handle full load draw, not startup. Smaller generator may pay for incremental cost of compressor.



ProblemsNewport• Thermister failed. Thermister was replaced and problem has not recurred.• Automatic Expansion Valve not tuned properly. Valve was adjusted and problem has not

recurred.

San Diego• Insulated Gate Bipolar Transistor (IGBT) failed. Decision was made to replace compressor

since it was relatively easy to do. Replacement took two hours. Problem has not recurred.

• Power surge damaged one of three compressors. Compressor was replaced. Manufacturer has stated that electronics have been improved since this compressor was installed.

• Electronics were not sealed sufficiently resulting in moisture damage. Sealing has been improved.

Jacksonville• None



Best Places To Install Magnetic Bearing Chiller Compressors

•Relatively high electric rates

•Long run hours at part load

•Where existing compressor is in need of replacement



Transition is never over until new technology is in the marketplace

•Stay in contact with the manufacturer•Stay in contact with end users


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