http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/RSS.ashxRefrigeration and Air Conditioning PagesThu, 27 May 2010 17:51:59 +0200http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=1maKIng modern lIVIng possIBle SolutionS t r e n d s a n d t o p I c s t h a t I m p a c t I n d u s t r y EnVisioneering SM The Global Energy Future hVacr Industry confronts an uncertain World Volume 9 / Issue 2 / 2010 engIneerIng + energy effIcIency + enVIronment = enVIsIoneerIng2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=2MAKING MODERN LIVING POSSIBLE Empower your solution with Danfoss Variable Speed compressors 200TR Turbocor® Large Commercial Applications Innovation Award AHR Expo 2003 2TR Performer® VSD Residential Applications Innovation Award AHR Expo 2010 20TR Performer® VSD Commercial Applications Innovation Award AHR Expo 2009 www.danfoss.com www.turbocor.com2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=3Volume 9 / Issue 2 Dear Readers, the future of energy, both on a global and a national scale, is uncertain. delegates to the 15th united nations climate change conference (cop15) last december in copenhagen failed to agree on a legally binding replacement of the Kyoto protocol. In the united states, energy legislation has taken a back seat to healthcare, the economy and jobs creation. and yet, while copenhagen did not produce a legally-binding global climate change agreement, it heightened awareness that energy efficiency is the most viable way to reduce carbon emissions, while saving money and reducing dependence on volatile foreign energy sources. and in the united states, lawmakers continue to pursue passage of comprehensive energy and climate change legislation that remains a priority for the obama administration. Just how certain is the future of global energy? this issue of envisioneering solutions looks at that question, beginning on page 2, as we examine “energy & climate policy: hVacr Industry confronts an uncertain World.” as energy experts, industrial leaders and governments around the world consider energy efficiency and carbon emissions, district energy, a system in which heating and cooling is produced centrally and distributed through pipes to multiple consumers, is securing its place in the future of global energy. an article on pages 6–9 explains where it’s working and the benefits it offers. meanwhile, three different facilities—a zoo, a food distributor and a business center—have taken steps today to secure their energy future tomorrow. learn how danfoss solutions are helping them increase operating efficiencies and enhance creature comforts, delivering impressive savings of both time and energy in the process. as always, we welcome your suggestions and feedback on this issue. the chester Zoo has seen a 78% energy savings since teaming up with danfoss and JBc controls to optimize energy use in its penguin enclosure, elephant house, and jaguar enclosure. story on page 14. Contents / 2 / FRom ThE CovER 2 / energy & climate policy: hVacr Industry confronts an uncertain World 6 / district energy attracting attention on global energy stage / 10 / CasE sTuDIEs 10 / danfoss provides link to ensuring Quality in distributor’s chain of custody 14 / Zoo realizes energy savings up to 78 percent and optimum conditions for elephants, Jaguars, and penguins 17 / small Valves Introduce Big changes to Building efficiency and occupant comfort / 20 / NEwswoRThy product hIghlIght thIs Issue Lisa Tryson, Editor solutions@danfoss.com Information contained in Danfoss EnVisioneering Solutions may be republished only with permission of Danfoss and always with credit to Danfoss EnVisioneering Solutions. Comments, suggestions and contributions are always welcome. This publication should not take the place of appropriate technical or legal advice related to company-specific circumstances. Danfoss EnVisioneering Solutions does not assume any liability of any kind whatsoever for the use or reliance upon the information contained in this publication. Vlt® profInet option card2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=4Energy & Climate Policy: W rl The global energy future seemed in January 2009 to have taken a clear and definite turn. The world looked to the new american administration and Congress for a new direction. Cap-and-trade energy legislation was on the drawing board. International negotiations on carbon and refrigerants were envisioned. Flush budgets in key states had produced what seemed a vanguard on energy efficiency regulation. and the Environmental Protection agency (EPa) had new leadership and a mandate from the supreme Court to regulate carbon. Uncertain H VA C R I n d u S T R y C o n F R o n T S2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=5The new uncertainty At the end of the year, the picture was very different. After passage in the House, comprehensive energy and climate change legislation moved slowly. The 60-vote rule hardened as a major obstacle to Senate action. Refrigerants were reviewed by the Montreal process and passed to Copenhagen, with uncertain consequences. The financial crisis had shattered state budgets. As 2010 began, three main paths seemed possible. A new round of international discussions on the 2012 expiration of the Kyoto Agreement was beginning. The U.S. legislative process still offered a window—if healthcare was addressed before the election season set in. And the EPA remained armed with its new authority. Most observers today concede that the international road is troubled and the legislative route difficult. Hovering above it all, the electoral tide that had seemed so decisively shifted in favor of action on energy and climate now seems poised to recede, and the financial and economic crises have left the debris of unemployment and precarious personal finances that now preoccupy policy makers. Whether one looks at carbon, refrigerants or new energy, a new uncertainty has taken hold. S An ld n Getting out the map Energy and climate remain top-tier priorities for the new administration and Congress, but not top of the tier. As 2010 began, healthcare, the economy, financial regulation and wars in Southwest Asia all came first. At the same time, the electoral scene shifted dramatically, with election results in Virginia, New Jersey and Massachusetts suggesting that Republicans will gain more seats than previously expected in November. The electoral shift reflects established historical patterns. But with Congressional passage of healthcare legislation amidst exceptional rancor, financial regulation second on the declared White House agenda, a Senate 60-vote rule locked in place by partisan discord, and general agreement that by July the legislature will be in election mode, the legislative path is looking crowded and complex. » Volume 9 / Issue 2 / 2010 32010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=6coVer story contInued The 2010 election represents more than just a timing issue. The standard axiom on Capitol Hill is no energy bills in election years – the issue is just too controversial and too many members come from states that either use or mine coal. Even if the Senate were not harnessed to the 60-vote rule, the majority party would have a hard time raising 50 votes for cap-and-trade. But much, too, depends on factors unrelated to energy and climate policy. At this writing, the parties are defining not just policy, but the dynamics of policymaking across the board. How those issues are settled will impact the prospects for everything else, including energy and climate legislation. William Wicker, communications director of the Senate Energy and Natural Resources Committee, outlined the current situation succinctly. The Committee reported out an energy bill in June 2009 after twelve markups and a bipartisan vote. Senate Majority Leader Harry Reid preferred to bundle energy and climate initiatives, following the House of Representatives procedure that produced the Waxman-Markey bill. But with no climate bill forthcoming in the Senate, progress stalled. an uncertaIn course as 2010 began, at least three main paths seemed possible in the fate of global energy and climate policy. 1 International a new round of international discussions on the 2012 expiration of the Kyoto agreement was beginning. hope in bipartisanship If the two parties decide to enter the election cycle in an embrace of bipartisanship—or at least to not harden into post-healthcare antagonisms—energy and climate legislation of some sort will have a better chance than if they enter the electoral arena amid deep controversy. The House Waxman-Markey bill is, of course, still on the table. If the Senate passed some bill, the two could be sent to conference committee to hammer out a resolution of the differences. And into that situation has stepped the tripartisan team of Senators Kerry, Graham and Lieberman, with an effort to put together a climate bill that can muster 60 votes. The President sought to encourage goodwill between the parties by committing money to nuclear power plants, a Republican favorite. In addition, a much pared-down “jobs bill” has passed the Senate that may be a model of how to proceed on energy and climate, with much that was controversial set aside. But on energy and climate, it is not clear that the left will vote for what the right will accept. And many observers now say the way healthcare was passed has “poisoned the well,” making progress on other issues very difficult, if not impossible. Senator Reid could decide to move ahead with energy legislation alone, perhaps with amendments. But the issue remains controversial, and the 60-vote rule and partisan contention could make passage worse than doubtful. 2 Legislative the u.s. legislative process still offered a window – if healthcare was addressed before the election season set in. 3 EPa the epa remains armed with its new authority. 4 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=7Taking stock and setting course The map of routes to a new energy future is marked by obstacles, risk and obscurity, but it is not without hope for progress. So the next question for industry is, What can be done? » First, for the private sector perhaps—acknowledge that investment, product development and sales strategy for energy efficiency technology all move forward amid deeply rooted uncertainty. It is hard today for anyone to speak with certainty about where things are going. » second, business action on energy in the policy arena will have the best chance of success if it recognizes the sources of uncertainty and the structure of the ambiguities ahead. each event will have consequences for itself and most other pieces of the complex puzzle. decisions on where and how to take action should be reviewed 360 degrees on an ongoing basis. » Third, the timeframe for business decisions needs to reflect the dynamics of the policy arena. a few years ago, those with technology in the ready were frustrated by the pace of change. a year ago, it seemed only the main points of a new approach needed to be sorted out. today, it is more evident that it is time for a second look at what it will take for industry to deliver on the energy requirements of the 21st century. We may have the means, but tenacity may be required to create the path. Independent of the policy process, the price of energy is expected to rise substantially. If so, it will transform the future energy marketplace and the way we use electrical power. The challenge and the opportunity remain on the horizon, irrespective of today’s policy process. Independent of the policy process, the price of energy is expected to rise substantially. If so, it will transform the future energy marketplace and the way we use electrical power. The challenge and the opportunity remain on the horizon, irrespective of today’s policy process. Private sector leaders need a wider array of options on how to make short-term markets reflect underlying economic realities and the long-term requisites of sustainability. Volume 9 / Issue 2 / 2010 52010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=8dISTRICT ENERGy at t r a c t I n g at t e n t I o n o n g lo B a l e n e r g y s ta g e today, 60 percent of the energy produced in the world’s power plants is wasted. more than one third of the energy produced in the european union (eu) alone is lost and never delivered to the consumer, according to districtenergypartnership.com, a website developed by logstor, coWI, grundfos and danfoss to increase awareness of and knowledge about district energy. m e a n W h I l e , c o 2 e m I s s I o n s are on track to increase by 50 percent in 25 to 30 years. As energy experts, industrial leaders and governments around the world grapple with these statistics, searching for technologies and solutions that will reverse an alarming trend, the idea of District Energy is beginning to take root, both in discussions and in practice. District Energy is a generic term for district heating and cooling. In a District Energy system, steam, hot water or chilled water is produced at a central plant and 6 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=9distributed through a network of insulated pipes to buildings in the “district” for space heating, domestic hot water and air conditioning. Water is returned to the plant to be reheated or chilled. Once a District Energy network has been established, it is compatible with any kind of energy source. In the past, fossil fuels, including coal, oil and natural gas, were the primary energy source for the system. Today, renewables such as biomass, solar or geothermal heating are gradually replacing or complementing more conventional fuels. What’s more, the conversion to a more environmentally friendly supply of energy takes place without the energy consumer ever noticing it. Cogeneration—also called combined heat and power (CHP)—makes District Energy systems even more efficient and environmentally friendly by capturing the heat that is produced as a byproduct in electricity generation and distributing it through the District Energy system. As a result, where singlepurpose power plants that produce only electricity convert just 40 percent of the fuel input to energy, » Volume 9 / Issue 2 / 2010 72010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=10coVer story contInued key terms “district energy:” Generic term for district heating and cooling in which steam, hot water or chilled water is produced at a central plant and distributed through a network of insulated pipes to buildings in the “district” for space heating, domestic hot water and air conditioning. dIstrIc t energy: CHP plants utilize an additional 50 percent for heat energy, rejecting just 10 percent into the environment. Consequently, District Energy is credited with saving at least 113 million tons of CO2 emissions per year. District Energy also supplies 6 percent of the global heat demand today. By doubling that number to 12 percent in the EU32 countries, annual CO2 emissions would decrease by 400 million tons, the total annual emissions from fuel combustion in France. In the United States, District Energy and CHP are not new ideas. In fact, the first commercially successful District Energy system was launched in Lockport, N.Y., in 1877. Today, according to Robert Thornton, president of the International District Energy Association (IDEA), District Energy and CHP is an idea whose time has come. “We face a combination of challenges—both energy costs and the threat of climate change—and DHC/CHP can deliver on both,” he said. In 2007, IDEA advocated for legislation within the Sustainable Energy Infrastructure Act which allocated $3.5 billion over five years to support the design, construction and development of clean District Energy and combined heat and power. Today the organization actively lobbies to secure policies, legislation and regulations that support District Energy. In Europe, District Energy and CHP is recognized as an important means to achieve CO2 reductions. It is central to the Renewable Energy Source (RES) directive, one of the most comprehensive political initiatives that was passed by EU in 2008 and calls for 20 percent CO2 reduction, 20 percent increase in energy efficiency and 20 percent of energy from renewable energy sources by 2020. Denmark is one of the world’s leading countries when it comes to combining heat and power supply in urban areas. In fact, 60 percent of all Danish households are linked to the District Energy network, making the country among the most energy-efficient countries in the world. Even as Denmark’s GNP has increased nearly 80 percent since 1980, the country’s energy consumption has remained at the same level during this same period of time. cogeneration: also called combined heat and power (ChP), this practice makes District Energy systems even more efficient and environmentally friendly by capturing the heat that is produced as a byproduct in electricity generation and distributing it through the District Energy system. Renewable Energy Source (RES) directive: one of the most comprehensive political initiatives that was passed by Eu in 2008 and calls for 20 percent Co2 reduction, 20 percent increase in energy efficiency and 20 percent of energy from renewable energy sources by 2020. International District Energy Association (IDEA): american organization that actively lobbies to secure policies, legislation and regulations that support District Energy.2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=11Denmark is one of the world’s leading countries when it comes to combining heat and power supply in urban areas. 60 percent of all Danish households are linked to the District Energy network, making the country among the most energy-efficient countries in the world. In Germany, District Energy has been used on a much smaller scale. Just 8 percent of German households are supplied with District Energy. However, in the north German city of Hamburg, that number is as high as 19 percent and growing. Energy supplier Vattenfall is committed to a massive extension of District Energy distribution lines connecting 30,000 additional homes, and the consolidation of the network north of Hamburg, connecting another 50,000 homes by 2020. It’s a trend that Jan Matzen, vice president, sales, Danfoss District Heating, supports. “Danfoss takes its role in keeping District Energy on the political agenda of future energy systems seriously,” Matzen noted. “Not only because it is the cornerstone of our business, but because it is an effective way to tackle the challenges the world faces in terms of safeguarding our planet.” Danfoss is the leading supplier of controls and heat transfer solutions for district heating and cooling applications. Its products facilitate optimum energy efficiency in the transition from District Energy to usable heating, hot water and air conditioning for the consumer while maintaining maximum comfort. 400 million Decrease in tons of total annual Co2 emissions in the Eu if District Energy were to supply 12 percent of global heat. Volume 9 / Issue 2 / 2010 92010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=12case study one proJect hIghlIghts » aK-255 controllers log and transmit live data via a secure Vpn connection. » standardization of programming provides temperature consistency at all locations » energy savings will pay for the new system in less than 24 months DIsTRIbuToR’s ChaIN oF CusToDy temperature monitoring and energy management services support eby-Brown facilities and transport vehicles n a p e r V I l l e , I l l I n o I s - B a s e d Eby-Brown distributes more than 11,000 name-brand products to convenience stores, grocery stores and other convenience-based retail operations located in 28 states east of the Mississippi River. Included in that list of products are as many as 1,000 items that need to be refrigerated or frozen during storage at one of the company’s seven distribution centers and in company vehicles during delivery to the 13,500 locations that comprise Eby-Brown’s customer base. Until recently, it was difficult for the nation’s third largest distributor of tobacco, candy and convenience items to monitor temperatures in freezers and coolers throughout its chain of custody and ensure the quality of its product offering. danfoss Provides Link to Ensuring Quality in 10 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=13“We had a variety of different monitoring systems being used throughout our seven distribution centers,” recalled Corky Pringle, senior service desk technician at Eby-Brown. “Vendors and logging systems varied from location to location, challenging us to provide data in a single, uniform format.” According to Pringle, the challenge grew when Eby-Brown committed to milk delivery to select customers. “When you agree to deliver milk, you’ve got to be able to do more than say you’re meeting temperature standards for milk storage and delivery. You’ve got to be able to prove it.” solution delivers products and service As Eby-Brown considered solutions that would ensure food quality during the storage and transportation of not only milk, but of all its refrigerated products, Danfoss emerged as a strong contender, impressing Eby-Brown with the solutions and the services the company offered. According to Erin Cousler, product marketing manager for Danfoss’ Food Retail Service, service is a critical component of the Eby-Brown project. “Yes, there is AK product involved,” she said. “The AK system controller features important control and monitoring functions, including alarms and an extensive history. But this project is about more than a specific product. It’s also about service and our ability to provide Eby-Brown management with information so decisions can be made to ensure food quality.” Inherent in the program’s objective to ensure food quality were additional benefits that encouraged Eby-Brown to increase the scope of work. The original project scope was to install Danfoss equipment at the Eby-Brown distribution centers in Ypsilanti, Mich., and Springfield, Ohio, and in temporary trailers that provide supplemental cold storage. Since then, Eby-Brown has extended the original purchase order to include three new elements: the installation of refrigeration equipment at all Eby-Brown distribution centers; a five-year agreement for full monitoring services; and temperature equipment and services for the EbyBrown fleet of 280 refrigerated transport vehicles. “We’re providing temperature monitoring services, which ensure food safety and quality and ultimately reduce product loss and shrinkage,” explained Cousler. “While our overall objective is to ensure food quality, Eby-Brown has realized additional benefits. From an operations “We’re providing temperature monitoring services, which ensure food safety and quality and ultimately reduce product loss and shrinkage” – erin cousler, product marketing manager, danfoss. standpoint, for example, our Remote Fix capabilities remotely monitor temperature alarms that indicate a potential food quality issue, determine the validity of these alarms, and make technical service recommendations to Eby-Brown based on the data received into our monitoring center.” “Alarm analysis and reporting is a tremendous operations savings for us,” said Pringle. “In the past, every alarm required someone from Eby-Brown to respond to the alarm. Refrigeration contractors would visit the distribution center, make sure everything was okay, clear the alarm and start over—even if it was just a short blip on the screen. “Now, if a system goes into alarm, Danfoss applies its refrigeration expertise to qualify alarms as either critical or noncritical alarms and responds appropriately. Responses to noncritical alarms are scheduled during normal business hours to avoid weekend and after-hour service calls and costs. From our perspective, this system has eliminated needless service calls and all the related stress.” web-based application provides immediate access to data Danfoss AK-255 controllers log temperature data from each Eby-Brown facility and transmit the data over a secure VPN connection. Using a web-based application called » Volume 9 / Issue 2 / 2010 112010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=14case study one contInued “Today, we monitor temperatures in our freezers, coolers, storage trailers and delivery vehicles 24/7, 365 days a year.” –corky pringle, senior service desk technician, eby-Brown Danfoss aK-255 controllers log temperature data from each Eby-brown facility and transmit the data over a secure vPN connection. using a web-based application called PowerFocus, Eby-brown enters a unique log-in to view temperature data on an enterprise level or by individual location at any given time, day or night. PowerFocus, Eby-Brown enters a unique log-in to view temperature data on an enterprise level or by individual location at any given time, day or night. This immediate access to regularly collected temperature data is important with respect to milk products and Hazard Analysis and Critical Control Points (HACCP) reporting. “USDA inspectors can arrive unannounced at any one of our facilities and require us to provide them with data that proves product has been consistently maintained at the proper temperature,” said Pringle. “In the past, we had to pull logs from whatever system was available at a facility and hope that the data these logs provided was sufficient for the inspector. The process could take days. “Today, we monitor temperatures in our freezers, coolers, storage trailers and delivery vehicles 24/7, 365 days a year. The data is recorded every 30-60 seconds. Data is maintained on- and off-site, so we’re able to go online and immediately bring up the reports inspectors require. It’s an advantage for us and goes a long way toward assuring our customers that they’re getting a quality product.” According to Cousler, Danfoss works with its customers to create dashboards and reports that give them the information they need to provide measurements important to them. “We don’t want to tell them what information is important,” she said. “We want our customers to tell us what they need to see, and how they want to see it.” what they knew was an issue—the inconsistency of naming and temperature set points across its distribution centers. Danfoss worked with Eby-Brown to establish a standard naming convention for its assets, based on the product it contained. This standardization allows for proper highand low-temperature set points to be programmed and for alarm thresholds to be set, ensuring food quality. Locked controllers prevent these temperature set points from being changed without authorization from corporate. Consistent asset temperatures have contributed to significant savings associated with equipment operation and maintenance at Eby-Brown. “Danfoss installed controllers on our freezer/cooler units that remotely monitor and adjust temperatures, ensuring more even cooling and preventing ice buildup, long defrost cycles and even longer cool-down periods while helping us reduce energy usage at our facilities,” said Pringle. “The energy savings alone—which we’ve conservatively estimated at 8 percent—will pay for the entire system in less than 24 months. And that doesn’t take into account the money we’re saving on equipment—things like servers that average twelve to thirteen thousand dollars—by not having to maintain our own data.” Danfoss goes on the road Fleet operation has also been impacted in a positive way. The transport refrigeration monitoring service Danfoss provides to Eby-Brown is unique. While competing systems download temperature data only when a truck arrives at its destination, the Danfoss AK Voyager system provides real-time data as the truck is on the road. Temperature standardization ensures food quality Additionally, the ability to view their locations on an enterprise level provides the data Eby-Brown needed to fix 12 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=15product hIghlIght data is posted every 15 minutes and color coded to reflect the temperature data related to predetermined set points. Custom reports can be developed, using this data, to satisfy regulatory and legislative requirements. In addition, temperature alerts indicate high and low temperatures as well as open doors. Fleet alerts are also part of the system, providing notification of system faults or battery disconnects. The data is posted every 30 minutes and color coded to indicate stationary and moving transport vehicles. The Danfoss solution ensures the food quality of Eby-Brown’s products and strengthens Eby-Brown’s bottom line in the process. In addition to collecting and presenting temperature data, the solution provides EbyBrown with the benefits of risk management, operational efficiencies and energy savings. The Danfoss refrigeration equipment has been able to collect, store and transmit volumes of temperature data. This data is posted to provide clear, concise pictures that assist with operational decisions and meet regulatory requirements for documentation. “Eby-Brown is good at distributing product,” said Cousler. “Danfoss is good at providing solutions to help customers like Eby-Brown better manage the environment in which their product is stored and delivered.” Pringle agreed, adding, “Danfoss has been able to guide us in areas where we didn’t have the expertise at a particular point in time to make decisions that were in our best interest. I think it’s obvious that we’re extremely satisfied with the service Danfoss has provided to us. We’ve got a monitoring system in place that records temperature. But just as importantly, we have a provider in Danfoss that is able to offer us advice on energy management and the intricacies of USDA and HACCP regulations. As a result, we have consistency from facility to facility and confidence in the integrity of our food chain.” Vlt® profInet option card Enhances vLT® automation Drive The new vLT® PRoFINET mCa120 option Card expands the Ethernet communication capabilities of the vLT® automationDrive to PRoFINETbased networks. this option card handles a single connection with an actual packet Interval down to 1 ms in both directions, positioning it among the fastest performing profInet devices in the market. additionally, the mca120 features a built-in web server for remote diagnostics and visual confirmation of basic drive parameters, as well as an email notifier that can send an email message to one or more recipients should certain warnings or alarms occur, and/or when those warnings or alarms are cleared. supported application protocols include profInet for control and parameter setting, http (hypertext transfer protocol) for diagnosis via the built-in web server, and smtp (simple mail transfer protocol) for email notification. the profInet option card also supports dhcp (dynamic host configuration protocol) for automatic Ip address configuration, ftp (file transfer protocol) for file upand download, tsc (transparent socket channel) for easy access to drive configuration data from danfoss’ mct 10, and dcp (discovery and configuration protocol) for making topology and neighborhood recognition and Ip-address assertion possible from a plc. first introduced in 2003, profInet is a proven and complete Industrial ethernet network solution for manufacturing automation. profInet is a member of a family of networks that implement the profInet protocol at its upper layers. It encompasses a suite of messages and services for a variety of manufacturing automation applications, including control, configuration and information. for more InformatIon: contact 800-621-8806 salesinformation@danfoss.com www.danfossdrives.com2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=16case study t Wo proJect hIghlIghts » zoo has achieved financial benefits associated with reduced running costs while improving animal welfare. » 55 percent of these savings are directly attributable to the drives Zoo REaLIZEs ENERGy savINGs uP To 78 PERCENT and optimum Conditions for Elephants, Jaguars and Penguins d a n f o s s V lt ® d r I V e s and a “demand matched” ventilation strategy have resulted in significant energy savings at The Chester Zoo. JBC Controls, in conjunction with Danfoss, installed variable speed drives in three of its animal enclosures: Spirit of the Jaguar, Elephants of the Asian Forest and Penguins. Existing systems were upgraded in order to save energy and increase efficiency. As Glyn Berry, sales director at JBC Controls, explained, “All drives have been retrofitted adjacent to the system they control. Because we were working with an existing system, we had to rewire fan supplies to comply with the current EMC directive and standards set out by Danfoss. The beauty of the drives being in IP55 enclosures meant there was no need to provide additional protective enclosures.” JBC Controls and Chester Zoo have a longstanding relationship that spans five years. This particular application is the largest, single energy-saving project the two organizations have undertaken to date, and looks to be the most rewarding. According to statistical data gathered since the installation of the drives, the zoo has achieved financial benefits associated with reduced running costs while improving animal welfare. 14 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=17http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=17Energy savings up to 78 percent in ventilation system The zoo is realizing its greatest success in the elephant house, where controls were optimized in August 2008 by installing an outside air temperature sensor to the BMS controls. With this addition, operating modes between summer and winter settings can be determined, based on ambient air. This optimization, combined with the installation of Danfoss VLT drives and a demand matched ventilation strategy, has resulted in documented energy savings as high as 78 percent—equal to 76 tons of CO2 emissions. Approximately 55 percent of these savings are directly attributable to the drives, which were installed in July 2008. This application also helped the zoo realize forecasted cube law savings. A 20 percent reduction in speed has reduced energy consumption in excess of 50 percent. The ability to control speed has also eliminated the motor start/stop noise that could potentially disturb the elephants—an unforeseen benefit that enhances animal welfare and impacts animal management in a positive way. the numbers chester Zoo proJect 79 tons 78% Projected annual Co2 savings in the penguin enclosure as a result of new Danfoss drives controlling water circulation to the pool area Documented energy savings in the elephant house as a result of optimized temperature controls vLT control of water filtration plant The water filtration plant in the penguin enclosure has three 18.5 kW drives (two duty and one standby) that control water circulation to the pool area and automatically reduce water flow to 70 percent at night via a time program. Improvements were not as dramatic as those recorded in the elephant house, but the positive effect was evident immediately after installation of the drives. To date, the average monthly energy savings in this area, totaling 40 percent, are directly attributable to the Danfoss drives. In addition, projected annual CO2 savings in the penguin enclosure are approximately 79 tons. Meanwhile, the zoo anticipates that within 12 months it may profit from a greater return on its investment than originally projected. Two additional unexpected benefits include reduced noise in the plant room and improved water quality, the result of more effective use of continuous ultraviolet light. In the jaguar enclosure, two drives (one 11 kW and one 7.5 kW) control the surrounding fresh air using a BMS control much like the one in the elephant area. Room temperature sensors also support the ventilation system by regulating heating and cooling demand. In addition, should the system be turned off, it is equipped to automatically respond to increases in the CO2 level. $4,500 Estimated reduction in monthly energy costs since the project’s completion » Volume 9 / Issue 2 / 2010 152010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=18http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=18case study t Wo contInued optimized efficiency due to demand matched controls strategy The application of drives at Chester Zoo has enabled the facility to optimize efficiency by adopting a demand matched controls strategy that reduces energy consumption of HVAC equipment in both the elephant house and the jaguar enclosure. Previously, motors ran 24 hours a day at one speed. Now, for the first time the zoo is able to match the speed of the motor (or the pump in the case of the penguin enclosure) to the demand of the system and switch off the air handling unit in response to changes in temperature or air quality. Ventilation and seasonal demands can now be easily met, with no adverse effect on environmental conditions. Improving environmental performance Ray Morrison, maintenance manager at Chester Zoo for 10 years, explained that environmental performance is just as important to the zoo as financial performance. “At Chester Zoo we adopt the principle of triple accounting. Our performance is measured by how well we perform financially, environmentally and in terms of corporate social responsibility.” Ray went on to explain that the zoo takes its responsibility for the environment very seriously. “Whatever money can be saved is more money that can be re-invested in animal welfare and conservation projects worldwide, such as supporting Asian elephants in their natural habitat in the wild.” As part of Chester Zoo’s compliance with Environmental Management Standard ISO14001, awarded to the facility in 2004, the zoo made the following pledge in its Environmental Policy statement: “to achieve such improvements in environmental performance, the Zoo has set, and will maintain, review and revise, environmental objects and targets with the aim of continually improving our environmental performance”. Chester Zoo is currently implementing its Energy Management Plan, aimed at delivering energy conservation and efficiency by developing operational and technological excellence in order to reduce environmental impact and control costs. Energy usage is constantly monitored using data loggers in various “high consumption” buildings to identify opportunities for renewable technologies. The buildings’ environmental assessment method BREEAM has also been adopted in relation to the zoo’s capital development program. The zoo’s long-term plan is to become carbon neutral, aiming for a 10 percent reduction in energy consumption, which represents a significant savings across Chester Zoo’s complex 110-acre site. The purchase of Danfoss VLT drives and their installation by JBC Controls is seen by all parties as a major step toward continual global environmental compliance and best practices, with an estimated $4,500 reduction in monthly energy costs at Chester Zoo. This long-term investment supports the zoo’s proven track record in demonstrating its significant contribution to the protection of animals and reinforces its dedication to sustainability. The zoo is realizing its greatest success in the elephant house, where controls were optimized in August 2008 by installing an outside air temperature sensor to the BMS controls. With this addition, operating modes between summer and winter settings can be determined, based on ambient air. all Danfoss facilities are Iso 14001 certified. 16 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=19http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=19case study three proJect hIghlIght » danfoss aB-Qm valves in the center’s heating and cooling system is having a positive impact on building performance buILDING EFFICIENCy & oCCuPaNT ComFoRT e n e r g y c o s t s a r e o n t h e r I s e in this country and around the globe. As a result, building owners and facility managers in all corners of the world are searching for new technologies to contain costs and reduce energy consumption in the buildings they manage. A leader in international commercial real estate development and management and owner of The Park business center, AIG/Lincoln is no exception. In the six years since it welcomed its first tenant, The Park business center in Chodov, a suburb of Prague in the Czech Republic, has become a magnet for hi-tech companies looking to establish offices in Eastern Europe. The center’s strategic location in the heart of the European Union, with access to transportation and a highly educated workforce, makes The Park attractive to IBM, Dell, Sony, Sun Microsystems, Accenture Services, DHL and other international tenants. Just as tempting to potential tenants are the state-of-the-art technologies that fill each of the 11 buildings that comprise the campus. Among them is a sophisticated building management system that controls and monitors mechanical and electrical systems, a high-speed fiber optic ring, cuttingedge fire and safety systems, and advanced heating and cooling systems that heat and cool 1,080,000 square feet of office space. Center owner AIG/Lincoln regularly assesses these systems, making adjustments where necessary and » Small Valves Introduce Big Changes to Volume 9 / Issue 2 / 2010 172010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=20http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=20case study three contInued introducing new technology when available, always with an eye to improving building performance and creating high-quality, cost-effective solutions for its clients. The incorporation of Danfoss AB-QM valves in the center’s heating and cooling system represents just such an introduction of new technology that is having a positive impact on building performance. AB-QM valves were introduced in the seventh building constructed at The Park, the result of a recommendation by Scheu + Wirth Praha, mechanical contractor for the project. “In the first six buildings, a three-way valve system required the entire heating, ventilation and air-conditioning (HVAC) system to operate at maximum flow,” explained Jürgen Winkler, a systems expert at Scheu + Wirth Praha. As a result, the HVAC systems used more energy than necessary, and pumps were required to work longer and harder, further increasing energy usage at The Park. “By introducing the AB-QM valves,” Winkler continued, “we were able to limit flow and, in the process, offer AIG/Lincoln increased system efficiency, improved flexibility and significant energy savings.” The incorporation of danfoss AB-QM valves in the center’s heating and cooling system represents just such an introduction of new technology that is having a positive impact on building performance. ab-Qm combines flow limiter and control valve The AB-QM pressure independent balancing and control valve (PIBCV) provides a flow limiter and a control valve in one compact package. This means the valve can be used as a stand-alone, automatic flow limiter valve or as a combined flow limiter and control valve when fitted with a wide range of actuators, providing accurate and stable flow in all cooling and heating applications. According to Winkler, the AB-QM valve introduced a number of benefits, beginning with ease of installation. The valve eliminates the need to install numerous control elements. As a result, installations of large HVAC systems with AB-QM valves can be accomplished in steps without requiring adjustment to already running parts. And, once a system or part is completed, it is ready for operation. The correct flow can be adjusted in one simple step, without the use of tools. “Building designers appreciate the simplicity of our solutions, while contractors are happy to eliminate installations of numerous controlling/adjusting elements in the whole system,” said Michal Kucera, Danfoss key account manager. “All that needs to be installed is a cooling system without any interim elements, plus terminal cooling units with our valves and a driving system.” The valves make it easy to make changes in the system, during either the design or installation stage or during operation. “In addition, adjusting the AB-QM control valves to optimum values is as simple as adjusting your watch,” said Kucera. The valve’s authority (or ratio between the pressure drop across the control valve compared to the total pressure drop across the whole circuit) no longer needs to be calculated, because the AB-QM features a unique design that ensures 100 percent authority with all settings and differential pressures. This increases quality and precision, leading to increased comfort in the building. 18 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=21http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=21The Park comprises Class a office space and a variety of landscape gardens and community spaces that provide 7,000 people with places to relax and meet with colleagues. “The automatic maximum flow limitation makes it possible to respond promptly and easily to changes in outside temperature or changes required by our tenants,” said Ales Knotek, AIG/Lincoln property manager. “And we can do that without making the extensive calculations and adjustments that were required in the past. The valve introduces an important element of flexibility that enables us to more closely meet the needs of individual tenants.” Additionally, more comfortable tenants mean fewer complaints and less servicing of the system. “In fact, the savings increased to as much as 52 percent during the month of May, when consumption was 21,569 kWh for a building without the AB-QM technology compared to 10,424 kWh for a building with the valves,” said Knotek. Savings like these made the decision to install AB-QM valves in all new buildings at The Park an easy one for AIG/Lincoln. To date, approximately 1,000 of the valves have been installed in six buildings, and an additional 300 have been ordered for the 12th building that is currently under construction. “In addition, based on the positive results at The Park, we selected the valves for inclusion in another project outside of Prague—Campus Square,” said Knotek. Located in nearby Brno, this 215,000-square-foot retail center includes more than 50 shops, a gourmet food court and a hypermarket, and is an important part of The Campus project, which includes an office and research and development complex. Here, as in The Park, the AB-QM valve is ensuring the efficient operation of the HVAC system by limiting flow and acting as a control valve. The Park comprises Class A office space and a variety of landscape gardens and community spaces that provide 7,000 people with places to relax and meet with colleagues. Outside, trees, plants and fountains work together to create a comfortable environment. Inside, a carefully designed HVAC system that incorporates AB-QM valves does the same thing, responding to the changing needs of building occupants precisely and promptly, without sacrificing energy efficiency in the process. What’s more, The Park supports AIG/Lincoln’s long-term business objectives of creating high-quality, cost-effective and timely financial and real estate solutions for its clients. valve delivers energy savings Just as significant are the energy savings attributable to the valves. According to Kucera, when compared to systems with three-way valves and a constant flow, variable flow systems that use AB-QM valves are more economical, providing exactly the correct amount of heating/cooling water to a terminal unit at any given moment. Savings are generated because circulation pumps work less and the operation is continuously optimized, in both lowload and maximum-load situations. Because AB-QM valves were not used in The Park’s first six buildings, owners were able to compare operating efficiencies between comparably sized and occupied buildings with AB-QM technology and without. Records indicate that during summer months, when the demand on the HVAC system was highest, buildings featuring AB-QM valve technology consumed, on average, 38 percent less electricity than buildings with standard valves. Volume 9 / Issue 2 / 2010 192010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=22http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=22NewsWoRTHy R E C E n T n E W S A n d u P d AT E S F R o M d A n F o S S danfoss flomatic Valves comply with lead-free legislation d a n f o s s f l o m at I c c o r p o r at I o n recently announced that its complete line of valve products is in full compliance with california and Vermont lead-free legislation that went into effect Jan. 1, 2010. this new legislation revised the term lead-free to refer not to the lead content of pipes and pipe fittings, plumbing fittings and fixtures, but to a weighted average lead content of the wetted surface area of the pipes, fittings and fixtures of not more than 0.25 percent. according to nick farrara, vice president of sales at danfoss flomatic, the company has taken a leadership role that will ensure continuous improvement in processes that impact the environment. “this is consistent with our environmental policy and our Iso 9001 and 14001 environmental registration. I’m convinced that in the future, unleaded materials with less than 0.25 percent lead will be a requirement in all markets.” danfoss flomatic is prepared to meet these requirements with its enviro bronze products. committed to providing products that exceed the requirements for lead content for decades, the company introduced the industry’s first unleaded bronze enVIro-checK® valves in 1996. these valves have been recognized as an acceptable material for california prop 65. nEW Slim-line Pressure Transmitters for Hydraulic Applications d a n f o s s ’ c o m pa c t, slim-line pressure transmitter series, mBs 8200 was developed for hydraulic applications demanding highest accuracy and insensitivity to temperature variations. also available with a pulse snubber, mBs 8200/8250 reveals a new technology making it capable of withstanding the pressure pulsations and vibrations known in mobile and industrial hydraulic applications. 20 enVIsIoneerIng solutIons2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=23http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=23suBscrIBe subscribe today by emailing solutions@danfoss.com to Solutions Today, technology is facing higher energy, environmental, and application demands that are putting pressure on how products and systems are designed and manufactured. In turn, engineering is being called upon for new concepts, technologies, and solutions, often provided by teams working collaboratively across disciplines and across geographic boundaries. EnVisioneeringsm Solutions tracks the latest innovations and provides up-to-date industry news. Subscribe to EnVisioneering Solutions by sending your full name and address to solutions@danfoss.com engIneerIng + energy effIcIency + enVIronment = enViSiOneerinG2010-05-27T17:51:59+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=24http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol9Issue22010/?Page=24DaNFoss LoCaTIoNs baLTImoRE, mD 11655 crossroads circle Baltimore, md 21220 410-931-8250 / fax: 410-931-8256 www.danfoss.us » refrigeration & air conditioning » Industrial controls » heating controls: 443-512-0266 fax: 443-512-0270 TaLLahassEE, FL danfoss turbocor 1769 e. paul dirac drive tallahassee, fl 32310 850-504-4800 / fax: 850-504-0280 www.turbocor.com » oil-free compressors for process and comfort cooling GLENs FaLLs, Ny danfoss flomatic Valves 15 pryun’s Island drive glens falls, ny 12801 800-833-2040 / fax: 800-314-3155 e-mail: flomatic@flomatic.com www.danfossflomatic.com » Water controls LovEs PaRK, IL 4401 n. Bell school road loves park, Il 61111 815-639-8600 / fax: 815-639-8000 www.danfossdrives.com » drives mILwauKEE, wI 8800 W. Bradley road milwaukee, WI 53224 414-355-8800 / fax: 414-355-6117 www.danfossdrives.com » drives » nessie high pressure Water systems mIssIssauGa, oNT 6711 mississauga rd., suite 410 mississauga, ontario l5n 2W3 905-285-2050 / fax: 905-285-2055 www.na.heating.danfoss.com » heating controls » motion controls mouNTaINsIDE, NJ danfoss hago, Inc. 1120 globe ave. mountainside, nJ 07092 908-232-8687 / fax: 908-232-7246 www.hagonozzle.com » components for oil Burners somERsET, NJ danfoss Bauer 31 schoolhouse road somerset, nJ 08873 732-469-8770 / fax: 732-469-8773 www.danfoss.com » geared motors W W W . d a n f o s s . u s 2010 Calendar of Events may 2010 » windpower Conference and Expo may 23-26, 2010 dallas, tX » offshore Technology Conference may 3-6, 2010 houston, tX » EE Global 2010 may 10-12, 2010 Washington dc convention center Washington, dc may 10-13, 2010 las Vegas, nV July 2010 » Purdue Compressor Engineering, » FmI 2010 » Envisioneering symposium: Refrigeration and air Conditioning, and high Performance and Green buildings Conferences and short Courses July 10-15, 2010 West lafayette, In Rx: systems approach to Net Zero may 13, 2010 Washington, dc Follow Danfoss Envisioneering on Twitter » twitter.com/danfossenvision Keep up-to-date on the latest news about Danfoss products and your industry at www.danfoss.us To find out more about Danfoss North america, contact us via email: solutions@danfoss.com2010-05-27T17:51:59+02:00