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DOE OSTI2011

CoolCalc: A Long-Haul Truck Thermal Load Estimation Tool

In the United States, intercity long-haul trucks idle approximately 1,800 hrs annually for sleeper cab hotel loads, consuming 838 million gallons of diesel fuel per year. The objective of the CoolCab project is to work closely with industry to design efficient thermal management systems for long-haul trucks that keep the cab comfortable with minimized engine idling. Truck engine idling isprimarily done to heat or cool the cab/sleeper, keep the fuel warm in cold weather, and keep the engine warm for cold temperature startup. Reducing the thermal load on the cab/sleeper will decrease air conditioning system requirements, improve efficiency, and help reduce fuel use. CoolCalc is an easy-to-use, simplified, physics-based HVAC load estimation tool that requires no meshing, hasflexible geometry, excludes unnecessary detail, and is less time-intensive than more detailed computer-aided engineering modeling approaches. It is intended for rapid trade-off studies, technology impact estimation, and preliminary HVAC sizing design and to complement more detailed and expensive CAE tools by exploring and identifying regions of interest in the design space. This paper describesthe CoolCalc tool, provides outdoor long-haul truck thermal testing results, shows validation using these test results, and discusses future applications of the tool.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2013

Fort Devens: Cold Climate Market-Rate Townhomes Targeting HERS Index of 40, Harvard, Massachusetts (Fact Sheet)

Achieving aggressive energy efficiency targets requires tight coordination and clear communication among owners, designers, builders, and subcontractors. For this townhome project, MassDevelopment, the quasi-governmental agency owner, selected Metric Development of Boston, teaming with the U.S. Department of Energy (DOE) Consortium for Advanced Residential Buildings (CARB) and Cambridge Seven Architects, to build very high performing market-rate homes. Fort Devens is part of a decommissioned army base in working-class Harvard, Massachusetts, approximately one hour northwest of Boston. The team proposed 12 net zero energy-ready townhomes, meaning that the application of renewable energy systems would result in annual net zero energy use in the homes. The homes were also designed to achieve a Home Energy Rating System (HERS) Index Score of 41 before adding renewables. For this project, CARB drew on its experience working with Rural Development Inc. on a series of affordable townhomes in northern Massachusetts. The team carefully planned the site to maximize solar access, daylighting, and efficient building forms. The basic strategy was to design a very efficient thermal enclosure while minimizing incremental cost increases compared with standard construction. Using BEopt modeling software, the team established the requirements of the enclosure and investigated multiple assembly options. They settled on double-wall construction with dense-pack cellulose fill. High performance vinyl windows (U-0.24, solar heat gain coefficient [SHGC]-0.22), a vented R-59 attic, and exceptional air sealing completed the package.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Smart building HVAC control challenge: experience and solutions from the ADRENALIN project

A smart building HVAC control competition crowdsourced and compared algorithms on fair and equal ground using the standardized BOPTEST framework. The competition attracted 138 participants, but only 9% submitted valid solutions for the final stage, highlighting the complexity of advanced HVAC control design. The winning solutions showed significant potential to reduce energy use and cost by shifting demand, without compromising occupant comfort. Across scenarios, thermal energy cost reductions of 36–76% relative to a baseline, were achieved. In peak heat periods, the cost reduction leveraged limited energy use reduction (0–15%), but more significant energy price reduction (34–62%). This shows smart controls' ability to avoid as much as possible consumption during the morning peak hours, when spot prices are tendentially the highest. Hosting the competition has highlighted challenges in creating competitions that both are fair and promotes solutions that are transferable to real life implementation.

BOPTEST↗

DOE OSTI2021

Multi-objective optimization of low-GWP mixture composition and heat exchanger circuitry configuration for improved system performance and reduced refrigerant flammability

The recently introduced hydrofluoroolefin (HFO) refrigerants, including R1234yf and R1234ze(E), have significantly lower global warming potentials (GWPs) than traditional hydrofluorocarbon (HFC) refrigerants like R410A. However, prior tests show that direct drop-in of pure R1234yf or R1234ze(E) into equipment designed for R410A results in a decrease in heat exchanger capacity and the system coefficient of performance. The primary reason is the lower in-tube heat transfer performance of R1234yf and R1234ze(E) compared with that of R410A. To address this issue, previous studies have mixed the mildly flammable HFC R32 with HFOs to improve system performance, with HFC R125 also added to suppress flammability. Previous studies selected compositions based on simple cycle analyses and did not consider modifications of the heat exchanger circuitry configuration to adapt to the new refrigerants. This study presents a novel multi-objective optimization approach to design a refrigerant composition that maximizes energy efficiency within flammability and GWP limits. The approach in this work simultaneously optimizes mixture composition and heat exchanger circuitry configuration. A case study on a rooftop unit indicates that, compared with mixture-only optimization, simultaneous optimization of mixture and heat exchanger circuitry yields a 5.9% improvement in cycle efficiency and a 48.6% reduction in refrigerant flammability with a GWP of 268. Circuitry optimization using refrigerants with different temperature glides shows that the larger the temperature glide is, the larger EER improvement is obtained. The results show that zeotropic blends with a large temperature glide are more sensitive to the refrigerant circuitry than pure refrigerants and may suffer significant performance degradation with subpar heat exchanger circuitry design. The proposed optimization approach is generally applicable to mixtures with any number of components. Using this approach to design a HVAC system can yield higher system efficiency within flammability and GWP constraints.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

Fort Devens: Cold Climate, Energy-Efficient, Market-Rate Townhomes

In 2009, Mass Development issued an RFQ and subsequent RFP for teams to develop moderately priced high-efficiency homes on two sites within the Devens Regional Enterprise Zone. MassDevelopment, a Massachusetts agency that owns the Devens site (formerly Fort Devens Army Base, in Harvard, Massachusetts), set a goal of producing a replicable example of current and innovative sustainable building practices with a near-zero energy potential. Metric Development, as primary developer and construction manager, formed one of the successful teams that included CARB and Cambridge Seven Architects (C7A).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2012

Extremely Low-Energy Design for Army Buildings: Tactical Equipment Maintenance Facility; Preprint

This paper describes the integrated energy optimization process for buildings and building clusters and demonstrates this process for new construction projects and building retrofits. An explanation is given of how mission critical building loads affect possible site and source energy use reduction in Army buildings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2013

Building America Top Innovations 2012: Ducts in Conditioned Space

This Building America Top Innovations profile describes Building America field testing that found moving ductwork into the home’s conditioned space can save 8%-15% on energy costs, improve comfort, reduce moisture problems, and even reduce installation costs.

Building America↗

DOE OSTI2021

Optimization of Refrigerant Compositions for Low-GWP Refrigerant Mixtures Using Segment-by-segment Heat Exchanger and Detailed System Models

Li, Zhenning↗

DOE OSTI2020

Energy and Exergy Analysis of Low-Global Warming Potential Refrigerants as Replacement for R410A in Two-Speed Heat Pumps for Cold Climates

Heat pumps (HPs) are being developed with a new emphasis on cold climates. To lower the environmental impact of greenhouse gas (GHG) emissions, alternate low global warming potential (GWP) refrigerants must also replace the exclusive use of the refrigerant R410A, preferably without re-engineering the mechanical hardware. In this paper, we analyze the performance of four low-GWP alternative refrigerants (R32, R452B, R454B, and R466A) relative to the conventional R410A and draw conclusions on the relative performances for providing heating in cold climates based on the Air-Conditioning, Heating, and Refrigeration Institute (AHRI) 210/240 standard for two-speed heat pumps. The simulations are carried using the Department of Energy, Oak Ridge National Laboratory (DOE/ORNL) Heat Pump Design Model (HPDM), a well-known heating, ventilation, and air conditioning (HVAC) modeling and design tool in the public domain and the HVAC research and development community. The results of the simulation are further scrutinized using exergy analysis to identify sources of systemic inefficiency, the root cause of lost work. This rigorous approach provides an exhaustive analysis of alternate low-GWP refrigerants to replace R410A using available compressors and system components, without compromising performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Designing reinforcement learning algorithms for building HVAC control: From experimental observation to simulation comparisons

Advanced supervisory-level control with reinforcement learning (RL) is regarded as a promising solution for HVAC systems to minimize energy consumption while maintaining thermal comfort and indoor air quality. However, most RL applications were conducted in the simulation environment rather than real-world HVAC systems. This paper developed a value-based RL controller termed Deep Q-Network (DQN) for a typical central HVAC system and evaluated its performance in a building test facility. By comparing DQN with a rule-based controller, the study not only demonstrated the cases where DQN could properly maintain indoor comfort but also discussed possible reasons why DQN failed in some other situations. Recognizing the limitations of value-based RL algorithms from the experimental tests, a simulation study was conducted to compare DQN with an alternative RL approach, an actor–critic algorithm termed Deep Deterministic Policy Gradient (DDPG). In scenarios with a relatively large action space, DDPG outperformed DQN by requiring fewer computational resources and achieving better thermal comfort, lower energy consumption, and more stable control actions. The findings suggest that the ability of DDPG to handle continuous control variables more effectively allows for faster convergence in training and more precise control in practice, which enhances the overall efficiency and reliability of the HVAC system.

Guo, Fangzhou↗

DOE OSTI2011

CNCC Craig Campus Geothermal Project: 82-well closed loop GHP well field to provide geothermal energy as a common utilitiy for a new community college campus

Colorado Northwestern Community College (CNCC) is working collaboratively with recipient vendor Chevron Energy Solutions, an energy services company (ESCO), to develop an innovative GHP project at the new CNCC Campus constructed in 2010/2011 in Craig, Colorado. The purpose of the CNCC Craig Campus Geothermal Program scope was to utilize an energy performance contracting approach to develop a geothermal system with a shared closed-loop field providing geothermal energy to each building's GHP mechanical system. Additional benefits to the project include promoting good jobs and clean energy while reducing operating costs for the college. The project has demonstrated that GHP technology is viable for new construction using the energy performance contracting model. The project also enabled the project team to evaluate several options to give the College a best value proposition for not only the initial design and construction costs but build high performance facilities that will save the College for many years to come. The design involved comparing the economic feasibility of GHP by comparing its cost to that of traditional HVAC systems via energy model, financial life cycle cost analysis of energy savings and capital cost, and finally by evaluating the compatibility of the mechanical design for GHP compared to traditional HVAC design. The project shows that GHP system design can be incorporated into the design of new commercial buildings if the design teams, architect, contractor, and owner coordinate carefully during the early phases of design. The public also benefits because the new CNCC campus is a center of education for the much of Northwestern Colorado, and students in K-12 programs (Science Spree 2010) through the CNCC two-year degree programs are already integrating geothermal and GHP technology. One of the greatest challenges met during this program was coordination of multiple engineering and development stakeholders. The leadership of Principle Investigator Pres. John Boyd of CNCC met this challenge by showing clear leadership in setting common goals and resolving conflicts early in the program.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Modeling Air Handling Units to Create a Diverse Fault Dataset for FDD Innovation: Lessons Learned and Recommendations

As energy management and information systems (e.g., automated fault detection and diagnostics [AFDD] tools) become more prevalent in the commercial building stock, it is important to determine the effectiveness of these technologies by benchmarking their performance. The authors have been working to develop the largest publicly available dataset of HVAC fault datasets for performance benchmarking applications, covering the most common HVAC systems and designs including chiller plants, rooftop packaged units, dual duct air handling unit and single duct air handling units. This study covers the development, modeling, and validation of a synthetic fault dataset for the air handling unit (AHU), one of the most common HVAC configurations found in the commercial building stock. Despite this being a common system, real-world time series data are scarce and usually do not span a wide range of weather conditions. Due to this limitation, two detailed AHU models, which included the single duct AHU and dual duct AHU developed in the Modelica language and HVACSIM+ were employed to carry out annual simulations of numerous common sensor faults, mechanical faults, and control sequence faults. The fault inclusive data were then validated by comparing fault effects on system performance to expected symptoms. We summarize the nature of each fault and their impacts under different weather and operation conditions. We report some lessons learnt during the efforts of validating the high volumes of the FDD data sets. Finally, we highlight considerations for FDD developers that may want to use this dataset to assess their algorithms’ performance and their improvement over time.

Casillas, Armando↗

DOE OSTI2022

Development of a Annual Air Handling Unit Fault Dataset for FDD Tools: Lessons Learned and Considerations for FDD Developers

As energy management and information systems (e.g., automated fault detection and diagnostics [AFDD] tools) become more prevalent in the commercial building stock, it is important to determine the effectiveness of these technologies by benchmarking their performance. The authors have been working to develop the largest publicly available dataset of HVAC fault data for performance benchmarking applications, covering the most common HVAC systems and designs including chiller plants, rooftop packaged units, dual duct air handling units and single duct air handling units. This study covers the development, modeling, and validation of a synthetic fault dataset for a single duct air handling unit (AHU), one of the most common HVAC configurations found in the commercial building stock. Despite this being a common system, real-world time series data are scarce and usually do not span a wide range of weather conditions. Due to this limitation, a detailed AHU model was employed to carry out annual simulations of numerous common sensor and mechanical faults, which were then validated by comparing their effects on system performance to expected symptoms. We summarize the nature of each fault and their impacts under different weather and operation conditions. Finally, we highlight considerations for FDD developers that may want to use this dataset to assess their algorithms’ performance and their improvement over time.

Casillas, Armando↗

DOE OSTI2012

Side-by-Side Field Evaluation of Highly Insulating Windows in the PNNL Lab Homes

To examine the energy, air leakage, and thermal performance of highly insulating windows, a field evaluation was undertaken in a matched pair of all-electric, factory-built “Lab Homes” located on the Pacific Northwest National Laboratory (PNNL) campus in Richland, Washington. The “baseline” Lab Home B was retrofitted with “standard” double-pane clear aluminum-frame slider windows and patio doors, while the “experimental” Lab Home A was retrofitted with Jeld-Wen® triple-pane vinyl-frame slider windows and patio doors with a U-factor of 0.2 and solar heat gain coefficient of 0.19. To assess the window, the building shell air leakage, energy use, and interior temperatures of each home were compared during the 2012 winter heating and summer cooling seasons. The measured energy savings in Lab Home B averaged 5,821 watt-hours per day (Wh/day) during the heating season and 6,518 Wh/day during the cooling season. The overall whole-house energy savings of Lab Home B compared to Lab Home A are 11.6% ± 1.53% for the heating season and 18.4 ± 2.06% for the cooling season for identical occupancy conditions with no window coverings deployed. Extrapolating these energy savings numbers based on typical average heating degree days and cooling degree days per year yields an estimated annual energy savings of 12.2%, or 1,784 kWh/yr. The data suggest that highly insulating windows are an effective energy-saving measure that should be considered for high-performance new homes and in existing retrofits. However, the cost effectiveness of the measure, as determined by the simple payback period, suggests that highly insulating window costs continue to make windows difficult to justify on a cost basis alone. Additional reductions in costs via improvements in manufacturing and/or market penetration that continue to drive down costs will make highly insulating windows much more viable as a cost-effective energy efficiency measure. This study also illustrates that highly insulating windows have important impacts on peak load, occupant comfort, and condensation potential, which are not captured in the energy savings calculation. More consistent and uniform interior temperature distributions suggest that highly insulated windows, as part of a high performance building envelope, may enable more centralized duct design and downsized HVAC systems. Shorter, more centralized duct systems and smaller HVAC systems to yield additional cost savings, making highly insulating windows more cost effective as part of a package of new construction or retrofit measures which achieve significant reductions in home energy use.

PNNL Lab Homes↗

DOE OSTI2013

Systems Evaluation at the Cool Energy House

Steven Winter Associates, Inc. (SWA) monitored several advanced mechanical systems within a 2012 deep energy retrofitted home in the small Orlando suburb of Windermere, FL. This report provides performance results of one of the home's heat pump water heaters (HPWH) and the whole-house dehumidifier (WHD) over a six month period. In addition to assessing the energy performance of these systems,this study sought to quantify potential comfort improvements over traditional systems. This information is applicable to researchers, designers, plumbers, and HVAC contractors. Though builders and homeowners can find useful information within this report, the corresponding case studies are a likely better reference for this audience.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

Systems Evaluation at the Cool Energy House

Steven Winter Associates, Inc. (SWA) monitored several advanced mechanical systems within a 2012 deep energy retrofitted home in the small Orlando suburb of Windermere, FL. This report provides performance results of one of the home's heat pump water heaters (HPWH) and the whole-house dehumidifier (WHD) over a six month period. In addition to assessing the energy performance of these systems, this study sought to quantify potential comfort improvements over traditional systems. This information is applicable to researchers, designers, plumbers, and HVAC contractors. Though builders and homeowners can find useful information within this report, the corresponding case studies are a likely better reference for this audience.

air conditioning↗

DOE OSTI2011

Advanced Strategy Guideline: Air Distribution Basics and Duct Design

This report discusses considerations for designing an air distribution system for an energy efficient house that requires less air volume to condition the space. Considering the HVAC system early in the design process will allow adequate space for equipment and ductwork and can result in cost savings. Principles discussed that will maximize occupant comfort include delivery of the proper amountof conditioned air for appropriate temperature mixing and uniformity without drafts, minimization of system noise, the impacts of pressure loss, efficient return air duct design, and supply air outlet placement, as well as duct layout, materials, and sizing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Energy Saving Estimation of ASHRAE Guideline 36 Supervisory Setpoint Reset Controls in a Commercial Large Office Building

Designing, commissioning, and retrofitting HVAC control systems for energy efficiency is crucial, but the use of ad-hoc control sequences by designers and contractors, based on scattered information, results in diverse and sub-optimal sequences. ASHRAE Guideline 36 (G36) addresses the challenge by providing standardized, rule-based HVAC control sequences that prioritize energy efficiency. However, there is limited evaluation of their energy performance at the building level, with only a few studies primarily focused on HVAC airside systems in small-to-medium-sized commercial buildings. In this study, the energy performance of ASHRAE Guideline 36 control sequences was assessed using a large office building emulator in Chicago. The emulator features a central plant system with multiple chillers and boilers as well as multiple variable air volume (VAV) systems with terminal reheat. To achieve a high-fidelity representation, we developed a Spawn-of-EnergyPlus-based model for the large office building, maintaining the DOE prototype large office building setup but substituting the HVAC system with its Modelica counterpart. This substitution ensures that the building thermal load, HVAC system's dynamics, and detailed control sequences are all accurately represented. The study involved evaluating and implementing control strategies outlined in ASHRAE Guideline 36-2021 to replace conventional controls. These strategies include the demand-based supply air temperature and duct static pressure setpoint reset and the request logic for demand-based reset of chilled/hot water supply temperature setpoints and pipe static pressure setpoints. Energy performance was evaluated under various load conditions, including cooling, heating, and transitional seasons, both for individual control strategies and in combination. The results indicate that the collective control strategies retrofit yield greater energy savings than the sum of individual strategies, highlighting the synergistic benefits of incorporating both airside and plant-side control retrofits. Additionally, energy savings of up to 41% in the heating season, 18% in the shoulder season, and 20 % in the cooling season were observed compared to baseline control while maintaining the thermal comfort level.

ASHRAE Guideline 36, Commercial buildings, Control↗