why retrofit your aging supermarket refrigeration ......• copeland digital technology is...

Why Retrofit Your Aging

Supermarket Refrigeration

Architecture?

E360 Webinar • August 13, 2019

Andre PatenaudeDirector — Solutions IntegrationEmerson

Speaker

2

Andre Patenaude, C.E.T. Director — Solutions Integration

Emerson

Andre is responsible for supporting system-related innovation and leveraging Emerson’s global cold chain to drive adoption of integrated solutions in North America. He most recently led marketing efforts pertaining to Emerson’s food retail and chiller markets. Prior to that, he had managed Emerson’s global CO2 development.

Andre has more than 34 years of industry experience in sales, marketing, training and business development of HVACR system architectures and applications with compression and component technologies. He is a certified Mechanical Engineering Technologist C.E.T. (since 1984), and is a member of ASHRAE, RSES and OACETT.

Technology Plays a Critical Role in Solving the

Industry’s Need for Food Safety and Quality

Harvest Processing Transportation Distribution Food Retail,

Foodservice

Key Technologies

• Compression/Systems

• Temperature Probes/Sensors

• Loggers/Trackers

• Connectivity Services

• Blockchain

Food Safety and Quality Needs

• Temperature Monitoring

• Verification Data

• Supply Chain Traceability

• Real-Time Insights

• Reporting and Documentation

Consistent temperature controlHandling

TransportationRegulatory requirements

MultipleplayersIntermediaries

Complexity

Customer Pain Points

E-commerce

TCO

Single view into my operationsLast-Mile Challenge

3

Why Is Power Management Important?

4

Energy and Power

FMI Energy SD 2018, Axiom Exergy

5

Super-peak Pricing

Summer super-peak pricing is in effect from June through

September on weekdays between 2 and 6 p.m.

Super-peak charges are significantly higher than supply charges

during the rest of the day. Save by opting to power down during

super-peak periods.

Time-of-Use RatesTiming is everything. Under our time-of-use rate, you’ll

pay less during off-peak periods than you would

under our standard small commercial or residential

rates, and more during peak and summer super-

peak times. See our time-of-use rate guides to learn

how much you and your business can save if you limit

energy use during peak and super-peak periods.

6

Peak Day Pricing combines a time-of-use

(TOU) rate with Peak Day Pricing Event

Day surcharges.

• There are 9 to 15 Peak Day Pricing “Event Days”

per year.

• An Event Day surcharge is added to the

regular TOU rate during peak hours from

2–6 p.m.

• Rates are discounted at all other times from May

1 to October 31.

Time-of-Use Rates

7

Trends and Drivers in the Energy Industry

9

Energy markets and demand response programs can generate substantial revenue for participants.

• Rise of renewables

and energy storage

• Time-of-use rate

structures

• Beneficial electrification

• Shift from lighting

rebates

ISO communicates that price is

about to increase from $0.1/kWh

to $1.0/kWh, unless 100 MW is

removed from the system.

Virtual Power Plant Scenario

Fundamentally, to enable transactions we must

commingle energy + information and assign value.

I’m a hotel with a big conference

underway. I need maximum cooling

for my building. I’m looking to buy

your additional load reduction to

avoid price increases.

I’m a big-box store, with variable-speed fans on

my RTUs. I can run those fans at somewhat lower

speeds for 10 minutes and “sell” you the load

reduction. It will make no noticeable difference

to my customers, and I can make some money

(part of the price increase the other customer

is avoiding).

1

2

3

• Example illustrates

concept of “across the

meter” coordination

• “Real-time” utility

pricing would be a driver

• Essentially, demand

response on steroids

with autonomous controls

• DOE supporting the

vision with demonstration

projects and research

DOE presentation on smart buildings, Nov. 2017 10

Convert your infrastructure into flexible energy assets and get paid for it.

Refrigeration

Food Waste

Recycling

Supervisory and

Building

Management

Enterprise

Monitoring

Cold Rooms

Lighting

Bakery

Evaporator

Controllers

HVAC

Cargo Monitoring

Ecosystem Management and Energy Costs

11

The user experience is now tailored to specific personas/tasks.

Enterprise-level Software Upgrade OpportunityVisualizations Are Solution-specific

• Provide only required information

– Apply comprehensive filtering criteria• Time, data type, asset type, location, limits, etc.

• Provide highly graphical, intuitive views

– Expand adoption to include non-domain experts

• Complete specific use-cases

– Color-coded map view of sites with two-click navigation to ID root cause• Include prescriptive corrective action(s)

12

Traditional

Centralized DX Rack

Why Upgrade Your Existing Supermarket Refrigeration Infrastructure?

Refrigeration52%

Lighting16%

HVAC19%

Other13%

Annual SupermarketElectricity Consumption

Supermarkets use

three times more energy

per square foot than other

retail facilities.

Typical Centralized DX

Sources: ENERGY STAR, AICA ENERGY

• Most common architecture

• Inflexible asset

• Many refrigerant options:– R-22, R-404A, R-407A/F (high-GWP)

• Thousands of feet of pipe

• 3,000+ pounds per system

• Highest average leak rates:

25% avg. (targeted by global

refrig. reg.)

• Highest CO2e or LCCP footprint

• Familiar, viewed as simple

Peculiarities

71% REF and HVAC

$7.7B in electricity per year

14

Traditional Supermarket System

Parasitic Losses

• Flash gas in liquid lines

• Insulation damage or cracking off

• Condensing pressure swings

• Excessive suction line superheat

• Excessive compressor cycling

• Improper TXV SH adjustment

• Hunting EPRs

• Small leaks

• Excessive defrost times

• Longer pull-down after defrost

15

Typical Aging Supermarket Racks

• Three old racks, more than 1,000,000 BTU

• 15 RTUs

• Five cond. units

16

The Journey to Energy Excellence — Effective vs. Efficient

En

erg

y E

ffic

ien

cy

Ongoing Performance Monitoring

Building/System

Project Concept

Design InstallationAdjustment Maintenance

Effective but NOT Efficient

Recommissioning/Optimization

Capital Upgrade

Latest Technology Efficiency

Deviation From OptimumLost E

ffic

iency

Time

Today

Maintain Optimum Efficiency and Effectiveness

17

Supermarket Optimization — Case Study

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Overview:

• 20-year-old, 45,000 sq. ft. grocery located in

southwestern Ontario

• Medium- and low-temperature centralized rack system

• System (total 164 hp) operates with 10 semi-hermetic

Copeland™ compressors

Objective:

• Analyze the energy impact of the medium- and low-

temperature racks of retrofitting one compressor on

each to a Digital Discus™ compressor

18

Step 1

Establish Baseline Energy

Energy Retrofit Opportunities

Journey to Energy Excellence

En

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Eff

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU

Upgrade

• Demand

Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital

• VFD

• Floating

Head/Suction

• Condensers

VFD

• Click and

Collect

20

Power Monitoring – Basic Need

Emerson

Emerson

21

Traditional Supermarket System

Good Poor

System Efficiency

22

Analysis Tools — Weather-Normalized Power Profile

Must measure baseline to understand effectiveness of upgrades and obtain utility incentives

Pre-optimization Energy Profile

Post-optimization Energy Profile

7°F 12°F 18°F 23°F 28°F 34°F 39°F 45°F 50°F 55°F 61°F 66°F 72°F 77°F 82°F 88°F

23

Step 2

Retro Commission Setpoints



En

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Eff

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU

Upgrade

• Demand

Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital

• VFD

• Floating

Head/Suction

• Condensers

VFD

• Click and

Collect

25

Supermarket OptimizationSetpoint Adjustment, Retro Commissioning – Case Study

Step B Step C Step DStep A

• 20-year-old,Toronto-area store identified

• 1,000,000 BTU capacity (163 HP: MT and LT racks)

• 900,000 kWh total

• 5 medium-temp Discus

• 5 low-temp Discus

• Install energy monitoring equipment to baseline the store energy

• Climacheck equipment being used

• Measure weather-normalized energy

• Adjust setpoints, superheat, high/low press. settings, comp. cut in/out, SH, etc.

• Spent $3,500 on boards and relays to change from two fans cycling at a time to individual fan cycling to 70 °F min. SCT

• Use energy-monitoring equipment and assure “continuous commissioning”

• As soon as readings vary away from energy setpoint, investigate the cause of the variance, re-adjust to original setpoints to maintain optimal energy

Results: 18% savings were maintained for 8-month period before new upgrades were performed.

18% = 162,000 kWh savings26



En

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Eff

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU Upgrade

• Demand Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital

• VFD

• Floating

Head/Suction

• Condensers VFD

• Click and Collect

27

Held the Savings8 Months

Saving 18%(162,000 kWh)

$0.14/kWh

$22,680

Step 3

Refrigeration Technology Upgrades Like Digital

What Is Digital?

• Copeland digital technology is fundamentally different from inverter-based modulation.

• The capacity modulation of the digital compressor is achieved by averaging the time between a “loaded state” and “unloaded state”.

• It is unique, reliable and very simple to apply.

Can also add a VFD to Discus (25–60 Hz range) AE21-1369 R4 29

Digital DiscusDigital Scroll™

29

50% Output 70% Output

Why Include Digital in Your Refrigeration Retrofit and Remodel Projects?

• Reduces compressor cycling

• Increases contactor life/system reliability

• Improves system load match capability

• Improves suction setpoint range

• Improves energy efficiency

• In some cases, suction setpoints are lowered to compensate for swings in suction pressure due to compressor cycling. By increasing the suction setpoint, an energy savings can be achieved.

• For every 1 PSI increase in suction pressure, compressor power is reduced by approximately 2 percent.

• Up to 30 percent more efficient than using hot-gas bypass

30

Supermarket Applications — Digital Upgrade MT Rack

Significant and immediate

reduction in compressor cycling

Digital Discus activated

72 psi 8 PSI

increase

Digital retrofit

89% reduction

in suction

pressure range

2D

3D

6D From 900 starts per day

to 12 starts in four days0

31

Step 3

Digital Upgrade –Results From Case Study

Supermarket Optimization Digital Discus Upgrade

Step F Step G Step HStep E

• Digital upgrade to MT and LT rack

• Establish worst-performing MT and LT compressor

• Ones with the highest discharge temps were identified as the worst

• New Digital Discus were used instead of adding a digital retrofit kit due to high discharge temp. issue

• Ran the new MT Discus Digital and new LT Discus Digital at full load for one month to record the actual energy advantage of two new “fixed” capacity Discus vs. two that were running with elevated discharge temperatures

• 4% savings

• Enabled Digital Discus for MT and LT rack using the E2 enhanced suction group

– Medium-temp. saving with Digital = 75,000 kWh

– Low-temp saving with Digital = 47,000 kWh

• 12% additional savings

• Further testing was never completed

• Plans were to:

– Change new condenser, M&V for energy baseline

– Upgrade to ECM motors on cond. and compare to baseline

– Was also planning to add EEV and case controls and compare to baseline TXV

Total Digital Discus upgrade saving was 16% or

122,000 kWh, $0.14/kWh = $17,080 saving

33



En

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Eff

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU Upgrade

• Demand

Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital or VFD

Compression

• Floating

Head/Suction

• Condensers

VFD

• Click and

Collect

34

Saving 18%(162,000 kWh)

$0.14/kWh

$22,680

Saving 16%

122,000 kWh

$0.14/kWh

$17,080

Digital Discus Compressor Upgrade Measurement and Verification

00

30.6 psig

31.4 psig

Pre Post

35

Digital Discus Compressor Upgrade Measurement and Verification (cont’d.)

36

58 psig

68 psig

Pre Post

36


37

Third-Party Energy Reporting

38


Step 3

Other Refrigeration

Additions or Upgrades



En

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Eff

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU Upgrade

• Demand

Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital or VFD

Compression

• Floating

Head/Suction

• Condensers

VFD

• Click and

Collect

Saving 18%(162,000 kWh)

$0.14/kWh

$22,680

40

Click-and-Collect Market Needs

Online Grocery Trend

41

42

Separate MT and LT Condensing Units Required

High Volume = Excessive Door Openings

Excessive Moisture – Potential Employee Safety Issue

Increase Consumer Demand Will Necessitate the Need for Walk-in

50% of consumers will not repeat business after a negative experience.42

“Lesson Learned” for C&C Volume

Differentiator

Complete Solution

++

Advanced

Condensing

Unit Controls

Remote Monitoring and Predictive Controls

Emerson Will

Work With Your

Preferred W/I Box

Supplier to

Deliver

the Solution.

43

Step 4

Medium-Temp.

Case Upgrades



En

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tio

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Eff

icie

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU Upgrade

• Demand

Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital or VFD

Compression

• Floating

Head/Suction

• Condensers

VFD

• Click and

Collect

45

Saving 18%(162,000 kWh)

$0.14/kWh

$22,680

Open

Closed

End User Benefits

• More than 60% reduction in energy (verified with M&V)

• Utilities rebate

• Tight temperature control

• Improved product quality

• Increased shelf life

• Warmer aisles, increased dwell times in aisles

Contractor Benefit

• Working on securing an additional 160 stores

Customer Pain

• High energy bills on 36’ of dairy case

• Large temperature swings in cases

• Latent pain, product quality and shelf life

Execution

• Added doors to 36’ of dairy cases

• Replaced 10 HP compressor with 5 HP Copeland

Digital Scroll

• Added XC634 Digital Scroll controller

Converting “Open” to “Closed” Cases in a Drugstore

46

Cold Thermal Energy Storage (CTES) — “kW” Saving

Axiom Exergy Viking Cold Rebound Technologies

47

Step 5

RTU Upgrades and

Demand Ventilation



En

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Eff

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU Upgrade

• Demand

Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital or VFD

Compression

• Floating

Head/Suction

• Condensers

VFD

• Click and

Collect

49

Saving 18%(162,000 kWh)

$0.14/kWh

$22,680

50

Commercial HVAC Solutions Focused the Underserved Units

North American commercial building energy savings potential is sizable. There are ~7.3 M > five-ton rooftop units in North America.

North America Rooftop

Units — Installed Base

Commercial Buildings With HVAC69%

Rooftop Penetration in Commercial Buildings58%

Addressable Market

Food-Related

Non-Food Related

23%

1,029k

77%

3,991k

Transformative Wave

Solution for Rooftop Units

• VFD Control

• Advanced

Economizer Control

• Cloud-enabled

• Fault Detection

and Diagnostics

Rooftop Units~2.9M

Rooftop Units~6.6M

Five-ton Rooftop~2.4M

Five-ton Rooftop~4.9M

AC Units~3.2M

AC Units~11.0M

25–50%

Energy

Savings

RTU Fault Detection and Monitoring

Rooftop Upgrade Kit

50

Step 6

Condition-Based

Energy Maintenance



En

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tio

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Eff

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Time

Current

State

Step 1

Baseline Energy

Audit

• Refrigeration

Setpoints

• Break/Fix Items

Step 2

Recommission to

Factory Specs

Future

State

Step 3

Refrigeration

Technology Upgrades

Step 4

Lighting and Other

Renewables Upgrades

Step 5

HVAC Technology

Upgrades

Step 6

Condition-based

Maintenance

6Energy Savings

• RTU Upgrade

• Demand

Control

Ventilation

• Adding Doors

• EEV, Cases

• ECM in Evaps

• CTES

• Digital or VFD

Compression

• Floating

Head/Suction

• Condensers

VFD

• Click and

Collect

52

Saving 18%(162,000 kWh)

$0.14/kWh

$22,680

Condition-based Maintenance

Regulations

Why Upgrade Your Existing Supermarket Refrigeration Infrastructure?

Refrigeration

Food Waste

Recycling

Supervisory

and Building

ManagementEnterprise

Monitoring

Cold Rooms

Cargo

Monitoring

Bakery

Evaporator

Controllers

HVAC

Leverage IoT

Power Management

1

2

3

Long-range Sustainability4

53

• Opportunities for energy efficiency are real, therefore savings available

• While each store is complex and unique, real-time, data-driven energy program allows for savings to be realized and proven

• Transforming energy-intensive supermarkets into a flexible asset is within your reach

Conclusion

54

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.

Thank You!

55

For further supermarket information, visit: Climate.Emerson.com/E360Webinar32

https://climate.emerson.com/en-us/industries/food-retail?utm_source=foodretail_and_grocery&utm_medium=industry_page&utm_campaign=august_webinar&utm_content=webinar

why retrofit your aging supermarket refrigeration ......• copeland digital technology is...

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