Reduce Monthly

Mohammad Shams,
Natural Gas
Seyed Alireza Tabatabaei,
Roozbeh Hojatpanah,
Farahmand,
Consumption Siavash
Shahriar Ahmadi Ghoohaki
HVAC
Department of

Y Statement

Reduce monthly natural gas

consumption by 20% for the months of
Dec thru Mar
Set

back temperature

Insulation

improvements

The Funneling Effect

Process Maps

C&E Matrix

30+ Inputs

All Xs

MEASURE

ANALYZE

IMPROVE

CONTROL

Failure Modes and Effects

Analysis
Multi-Vari Studies

10 - 15

1st Hit List

8 - 10

Screened List

Design of Experiments (DOE)

4-8

Found Critical Xs

Control Plans

3-6

Controlling Critical Xs

Critical Input Variables

Does the Setup Measure

Energy Consumption
Accurately

For each of the 24 hr data set

Calculate

the heater on time

Calculate

heating degree days

Plot

HDD vs. heater on time

Does it show a linear behavior

Analysis

Heater on Time vs HDD

Date
22-Jan
28-Jan
29-Jan
3-Feb
4-Feb
5-Feb
6-Feb

Total Heater On Time

Total Heater On

Calculated

Theoretical

Error percent

(hrs)
0.284
1.325
1.328
0.828
1.0465
1.185
1.057

Time (days)
0.011833333
0.055208333
0.055333333
0.0345
0.043604167
0.049375
0.044041667

HDD
30.05351743
49.58732704
50.30495225
36.87681015
33.9020865
32.6507873
42.25509352

HDD
30
48
50
37
35
32
41

0.178391443
3.306931342
0.609904497
0.332945553
3.136895702
2.033710322
3.061203695

Analysis
Heater on Time vs HDD
Calculated HDD vs. Total Heatre On Time
60

y = 382.75x + 23.306

50

R = 0.5049

Calculated HDD

40

30

Calculated HDD
Linear (Calculated HDD)

20

10

0
0

0.01

0.02

0.03

0.04

Total Heater on Time (days)

0.05

0.06

Analysis

Heater on Time vs HDD

Caculated HDD vs. Actual HDD
60
y = 1.0555x - 1.788

50

R = 0.9906

40
Calculated HDD
30

Linear (Calculated HDD)

20

10

0
0

10

20

30

40

50

60

Analysis

Error Percent of Heater on Time vs HDD

Error percent
3.5
3
2.5
2
Error percent

1.5
1
0.5
0
22-Jan

28-Jan

29-Jan

3-Feb

4-Feb

5-Feb

6-Feb

Therms Analysis
Total Heater On

Total Heater On

Calculated

Time (hrs)
0.284
1.325
1.328
0.828
1.0465
1.185
1.057

Time (days)
0.011833333
0.055208333
0.055333333
0.0345
0.043604167
0.049375
0.044041667

HDD
30.05351743
49.58732704
50.30495225
36.87681015
33.9020865
32.6507873
42.25509352

Theoretical HDD

Error

30
48
50
37
35
32
41

percent
0.178391
3.306931
0.609904
0.332946
3.136896
2.03371
3.061204

Energy Consumption (BTU)

Energy Consumption

18744
87450
87648
54648
69069
78210
69762

(Therms)
0.18744
0.8745
0.87648
0.54648
0.69069
0.7821
0.69762

Date
22-Jan
28-Jan
29-Jan
3-Feb
4-Feb
5-Feb
6-Feb

Total Heat loss for heating season (9 months) : (from the excel file)
BTU/hr
BTU
Therm
-8934.34
-58704867.84
-587.0486784

Total Heat loss for heating season (9 months) : (from the excel file)
BTU/hr
BTU
Therm
-8934.34
-58704867.84
-587.0486784

Total Heat loss for January : (from the excel file)

BTU/hr
BTU
Therm
-992.7044444
-6522763.093
-65.22763093

Total Heat loss for February : (from the excel file)

BTU/hr
BTU
Therm
-992.7044444
-6522763.093
-65.22763093

Average Daily Heat Loss for January: (form the excel file)
BTU/hr
BTU
Therm
-32.02272401
-210411.7127
-2.104117127

Average Daily Heat Loss for February: (form the excel file)
BTU/hr
BTU
Therm
-35.45373016
-232955.8248
-2.329558248

Measurement Error

Error due to long signal wires

Filter design
Impact

on mean value

Initial Capability

Initial capability
What

is the current energy usage as

baseline where savings will be calculated
from

Degree day comparison

Past 5 to 10 years gas and electric bills (kWhr used not $$$)

Calculate

heat loss from the house using

the excel analysis tool

Make the tool more general to include individual rooms

Run

transient heat transfer analysis using

the Matlab tool and compare to measured

Energy Cost Estimation

Date

Total Heater On Time (hrs)

Total Heater On Time (days)

22-Jan
28-Jan
29-Jan
3-Feb
4-Feb
5-Feb
6-Feb

0.284
1.325
1.328
0.828
1.0465
1.185
1.057

0.011833333
0.055208333
0.055333333
0.0345
0.043604167
0.049375
0.044041667

Calculated HDD
30.05351743
49.58732704
50.30495225
36.87681015
33.9020865
32.6507873
42.25509352

Theoretical HDD

Error percent

Energy Consumption (BTU)

Energy Consumption (Therms)

Energy Cost $

30
48
50
37
35
32
41

0.178391443
3.306931342
0.609904497
0.332945553
3.136895702
2.033710322
3.061203695

18744
87450
87648
54648
69069
78210
69762

0.18744
0.8745
0.87648
0.54648
0.69069
0.7821
0.69762

5745.036
26803.425
26864.112
16749.612
21169.6485
23971.365
21382.053

Results
q
Number of peaks =29
100

90

80

70

60
T_Out
50

T_Reg
T_Room
Humidity

40

30

20

10

0
0

10

11

12

Jan 22nd

13

14

15

16

17

18

19

20

21

22

23

24

The cost for one day at

these temperatures is:
$0.33
The optimal day time
temperature is: 51
Degrees F
The total running time
per day is: 97 Minutes

Results
q
Number of peaks =51
100

90

80

70

60

T_Out
T_Reg

50

T_Room
Humidity
40

30

20

10

0
0

10

11

12

Jan 28th

13

14

15

16

17

18

19

20

21

22

23

24

The cost for one day at

these temperatures is:
$0.13
The optimal day time
temperature is: 59
Degrees F
The total running time
per day is: 38 Minutes

Results
100

Number of peaks =59

90

80

Jan 29th

70

60

T_Out

50

T_Reg
T_Room
Humidity
40

30

20

10

0
0

10

11

12

13

14

15

16

17

18

19

20

21

The cost for one day at these

temperatures is: $0.18

The optimal day time

temperature is: 47 Degrees F

The total running time per day

is: 53 Minutes

22

23

24

Results
100

Number of peaks =33

90

80

Feb 3rd

70
T_Out

60

T_Reg
T_Room

50

Humidity

40

30

20

10

0
0

10

11

12

13

14

15

16

17

18

19

20

21

The cost for one day at these

temperatures is: $0.24

The optimal day time temperature

is: 48 Degrees F

The total running time per day is:

71 Minutes

22

23

24

Results
Number of peaks =48
100
90
80

Feb 4th

70
60
T_Out
T_Reg

50

T_Room
Humidity

40
30
20
10
0
0

10

15

20

The cost for one day at

these temperatures is:
$0.28

The optimal day time

temperature is: 50
Degrees F

The total running time per

day is: 83 Minutes

25

Results
Number of peaks=57
100
90
80

Feb 5th

70
60
T_Out
50

T_Reg
T_Room

40

Humidity

30
20
10
0
0

10

11

12

13

14

15

16

17

18

19

The cost for one day at

these temperatures is:
$0.27

The optimal day time

temperature is: 50
Degrees F

20

21

22

23

24

Results
Number of peaks=50
100
90
80
70
60
T_Out
50

T_Reg
T_Room

40

Humidity

30
20
10
0
0

10

11

12

13

14

15

16

17

The cost for one day at

these temperatures is:
$0.22

The optimal day time

temperature is: 49
Degrees F

18

19

20

21

22

23

24

Feb 6th

Heat Exchanger
Design

Mohammad Shams,
Seyed Alireza Tabatabaei,
Roozbeh Hojatpanah,
Siavash Farahmand,
Shahriar Ahmadi Ghoohaki

Department of

Design Parameters

Process Fluid
Water
Inlet

45C

Outlet

City Water
Inlet

25C

20C

Optimal Length Less Than 7 meters

Effective Variables
Effective Variables
Tube Thickness
Shell Thickness
Shell Material
M-dot Tube

M-dot Tube

Shell I/D

Shell I/D

Tube Length

Tube Length

Counter / Parallel
Tube O/D

Tube O/D

Tube Material

Due to previous iterations these nine were the variables that had the
greatest effect on Weight, Length, Q, and Ps

Generated Matlab File

Initial Inputs Generating

Plots of Main Effect

Pareto Charts for

Optimization

Shell side pressure drop- Shell I/D had the greatest effect

Heat
Heat Exchanger
Exchanger overall
overall weightweight- Shell
Shell I/D
I/D and
and Tube
Tube Length
Length
Tube pressure drop- Mass flow rate through the tubes, Shell I/D and Tube Length
Tube pressure drop- Mass flow rate through the tubes, Shell I/D and Tube Length

Pareto Charts for

Optimization

Optimization Plot

Optimization Results
Tube Side Heat Transfer Parameters
Number of Tubes, N
4169
Number of Passes
1
Tubes OD
0.0063 m
Tubes ID
0.0054 m
Tube Length, L
4.4000 m
Tube Pitch, PT
0.0079 m
Heat Transfer Coefficient, h
4158.44 W/m2.C

Overall Heat Transfer Coefficient

U (Tube outside Area)
1739.11 W/m2.C
Heat Transfer Rate
Desired Heat Transfer Rate
5106273.07 W
Calculated Heat Transfer Rate
5133356.91 W
Difference
-27083.84 W
Desired - To - Calculated Ratio
0.99

Shell Side Heat Transfer Parameters

Shell ID
0.5398 m
Shell Cross Sectional Area
0.2289 m2
Shell Flow Area
0.1059 m2
Shell Equivalent Diameter
0.0046 m
Mass Velocity, G
1028.84 kg/m2.s
Heat Transfer Coefficient, h
4419.42 W/m2.C

HE Pressure Drop
Shell Side P
85606.84 Pa
Tube Side P
8115.88 Pa
Heat Exchanger Weight
Total Weight
1362.78 kg

Adjusted Optimized Results

Tube Side Heat Transfer Parameters
Number of Tubes, N
3881

Shell Side Heat Transfer Parameters

Shell ID
0.5462 m

Number of Passes
Tubes OD
Tubes ID

1
0.0062 m
0.0053 m

Shell Cross Sectional Area

0.2343 m2

Shell Flow Area

Shell Equivalent Diameter

0.1084 m2
0.0045 m

Tube Length, L

4.2759 m

Mass Velocity, G

1006.65 kg/m2*s

Tube Pitch, PT
Heat Transfer Coefficient, h

0.0077 m
4087.62 W/m2*C

Overall Heat Transfer Coefficient

U (Tube outside Area)
1715.16 W/m2*C
Heat Transfer Rate
Desired Heat Transfer Rate
5106273.07 W
Calculated Heat Transfer Rate
5163877.58 W
Difference
-57604.51 W
Desired - To - Calculated Ratio
0.99

Heat Transfer Coefficient, h

4383.64 W/m2*C

HE Pressure Drop
Shell Side P

85674.36 Pa

Tube Side P

7956.80 Pa

Heat Exchanger Weight

Total Weight

1360.46 kg

Questions