- Refrigerated spaces cost 2-3X more to operate than normal spaces.
- Over 50% of the refrigerated facilities in the U.S. are operating with inefficiencies.
- Refrigeration Efficiency projects make up only about 5% of all Energy Efficiency projects in the country.
- Evaporator fans motors are generally Permanent Split Capacitor or 3 Phase motors. Both are inefficient technologies that were developed over 50 years ago, and consume massive amounts of electricity. Those motors typically run at high speed 24/7/365, pouring heat as wasted energy into refrigerated spaces which makes compressors run more often to remove the heat which is a very counterproductive cycle.
- Condenser fan motors in most applications, unless they are new, are also typically inefficient in design. These grouping of motors are sometimes set to turn on at the same time with the compressor, which causes a major spike in your electric Demand usage and billing that can be carried on your billing for months up to one year.
- Older style single speed compressors are still being installed today, but are prevalent in systems older than 10 years. The large motors that power these units also cause spike in Demand, and run at full boar regardless what the system is calling for in terms of volume, thus wasting energy every time they turn on.
- Chiller systems are not often optimized to run at their peak efficiency, which not only negatively affects your electric bill but also cause unnecessary maintenance and premature failure to an extremely costly system.
- Medium temperature Air Conditioning Roof Top Units receive little attention until they are broken, and a great deal of fixes to these units over the years reduce their efficiency, such as disconnecting economizers, and inaccurate refrigerant charges.
- Since there is such a large cost to operating refrigerated spaces, and there is a great deal of waste in most systems, businesses pay an excess of electricity to their provider year after year after year.
- Inefficient motors and lack of controls or proper settings cause extra wear and tear on the entire system, which increases life-cycle maintenance costs.
- Lastly, a facility full of evaporator fans running at high speed all of the time causes a drastic increase in noise levels which not only reduce workplace safety, but decrease employee productivity and morale over time.
- Replace all inefficient evaporator fan motors with 2 speed or variable speed Electronically Commutated Direct Current motors.
- Add control devices to evaporators to control the fan motors in that evaporator. New high efficiency evaporator fans run at high speed, and at low speed when the compressor duty cycle is off. This will dramatically reduce your kWh usage.
- Replace existing condenser fan motors with single speed EC motors, and stage them correctly with soft starts to minimize Demand charges.
- Replace old compressors with variable speed scroll or screw compressors which use brushless permanent magnet motors that precisely adjust to cooling loads
- Chiller systems: Measure the flow rate to determined and maintain the optimal Delta T to operate at peak efficiency. A Belimo energy valve is a good retrofit for this. Increasing the chill water temperature is a small but effective efficiency measure. Furthermore, ongoing cleaning and a water treatment program can improve efficiency. Finally, a refrigerant analysis can determine it’s oil content and level which can both lower efficiency.
- Retrocommissioning: thoroughly examining the equipment for correct operation, and restoring the units back to the original manufacture operational specifications.
- Simple tweaks to optimize existing system efficiency: Reduce minimum condensing pressure & defrost condensing pressure, and Night and/or weekend suction pressure set back.
SEE HOW AN EVAPORATOR FAN MOTOR & VARIABLE AIR VOLUME CONTROL RETROFIT WORKS
Our S.M.A.R.T. CEW turnkey process is to Save, Measure, Analyze, Replace and Transform. Here’s how:
- Collect existing system data and electric bills from customer. We provide complete instruction.
- We can design an energy efficient motor and controls upgrade for existing evaporators/condensers without coming onsite. Compressor and chiller analysis will be performed by one of our engineers onsite.
- Run energy calculations to identify the, cost savings and Paybacks of retrofit/replacement options, and create an Investment Model proposal to review.
- Work with utility provider engineers to verify savings and secure available utility incentives for projects.
- Specify, order and manage Installation and on-site Project Management to oversee project, including pre and post data logging Measurement and Verification.
- Reconcile project to include data logging savings analysis, available utility incentives, and create a case study to share customer’s sustainability story.
To start, schedule a 15 minute discussion with one of our Energy Analysts to determine how we can help your business, and discuss the steps to determining the best path to take.