REDUCE MONTHLY

NATURAL GAS Mohammad Shams,

Seyed Alireza Tabatabaei,
CONSUMPTION Roozbeh Hojatpanah,
Siavash Farahmand,
HVAC Shahriar Ahmadi Ghoohaki

Department of Mechanical Engineering, IUPUI

ME 414 Thermal-Fluid Systems Design
Fall 2010, Professor John Toksoy
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 30+ Inputs All Xs

MEASURE
C&E Matrix 10 - 15 1st Hit List

Failure Modes and Effects

ANALYZE Analysis 8 - 10 Screened List
Multi-Vari Studies

IMPROVE Design of Experiments

4-8 Found Critical Xs
(DOE)

CONTROL 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

Total Heater On Time Total Heater On Calculated Theoretical Error percent

Date
(hrs) Time (days) HDD HDD
22-Jan 0.284 0.011833333 30.05351743 30 0.178391443
28-Jan 1.325 0.055208333 49.58732704 48 3.306931342
29-Jan 1.328 0.055333333 50.30495225 50 0.609904497
3-Feb 0.828 0.0345 36.87681015 37 0.332945553
4-Feb 1.0465 0.043604167 33.9020865 35 3.136895702
5-Feb 1.185 0.049375 32.6507873 32 2.033710322
6-Feb 1.057 0.044041667 42.25509352 41 3.061203695
Analysis
Heater on Time vs HDD
Calculated HDD vs. Total Heatre On Time
60

50 y = 382.75x + 23.306
R2 = 0.5049

40
Calculated HDD

30
Calculated HDD
Linear (Calculated HDD)
20

10

0
0 0.01 0.02 0.03 0.04 0.05 0.06

Total Heater on Time (days)

Analysis
Heater on Time vs HDD
Caculated HDD vs. Actual HDD
60

y = 1.0555x - 1.788
50 R2 = 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

2.5

Error percent
1.5

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 Theoretical HDD Error Energy Consumption (BTU) Energy Consumption
Date
Time (hrs) Time (days) HDD percent (Therms)
22-Jan 0.284 0.011833333 30.05351743 30 0.178391 18744 0.18744
28-Jan 1.325 0.055208333 49.58732704 48 3.306931 87450 0.8745
29-Jan 1.328 0.055333333 50.30495225 50 0.609904 87648 0.87648
3-Feb 0.828 0.0345 36.87681015 37 0.332946 54648 0.54648
4-Feb 1.0465 0.043604167 33.9020865 35 3.136896 69069 0.69069
5-Feb 1.185 0.049375 32.6507873 32 2.03371 78210 0.7821
6-Feb 1.057 0.044041667 42.25509352 41 3.061204 69762 0.69762

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

Total Heat loss for January : (from the excel file) Total Heat loss for February : (from the excel file)
BTU/hr BTU Therm BTU/hr BTU Therm
-992.7044444 -6522763.093 -65.22763093 -992.7044444 -6522763.093 -65.22763093

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

Date Total Heater On Time (hrs) Total Heater On Time (days) Calculated HDD Theoretical HDD Error percent Energy Consumption (BTU) Energy Consumption (Therms) Energy Cost $
22-Jan 0.284 0.011833333 30.05351743 30 0.178391443 18744 0.18744 5745.036
28-Jan 1.325 0.055208333 49.58732704 48 3.306931342 87450 0.8745 26803.425
29-Jan 1.328 0.055333333 50.30495225 50 0.609904497 87648 0.87648 26864.112
3-Feb 0.828 0.0345 36.87681015 37 0.332945553 54648 0.54648 16749.612
4-Feb 1.0465 0.043604167 33.9020865 35 3.136895702 69069 0.69069 21169.6485
5-Feb 1.185 0.049375 32.6507873 32 2.033710322 78210 0.7821 23971.365
6-Feb 1.057 0.044041667 42.25509352 41 3.061203695 69762 0.69762 21382.053
 Results
Number of peaks =29
The cost for one day at these
100
temperatures is: $0.33
90

80 The optimal day time

70 temperature is: 51 Degrees F
The total running time per day
60

T_Out
50 T_Reg

40
T_Room
Humidity
is: 97 Minutes
30

20

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Jan 22nd
 Results
100
Number of peaks =51
The cost for one day at these
90
temperatures is: $0.13
80

70
The optimal day time
60 temperature is: 59 Degrees F
T_Out

The total running time per day

T_Reg

50
T_Room
Humidity

40

30
is: 38 Minutes
20

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Jan 28th
 Results
100
Number of peaks =59

90

80

70

Jan 29th
60

T_Out
50
T_Reg
T_Room
Humidity
40

30

20

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

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
 Results
100

Number of peaks =33

90

80

70 Feb 3rd
T_Out
60
T_Reg
T_Room
50
Humidity

40

30

20

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

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
 Results
Number of peaks =48
100

90

80

Feb 4th
70

60
T_Out

50 T_Reg
T_Room

40 Humidity

30

20

10

0
0 5 10 15 20 25

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
 Results
Number of peaks=57
100

90

80

70
Feb 5th
60
T_Out
50 T_Reg
T_Room
40
Humidity

30

20

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

The cost for one day at these

temperatures is: $0.27
The optimal day time temperature
is: 50 Degrees F
The total running time per day is:
79 Minutes
 Results
Number of peaks=50
100

90

80

70

60

50
T_Out
T_Reg
Feb 6th
T_Room
40
Humidity

30

20

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

The cost for one day at these

temperatures is: $0.22
The optimal day time temperature
is: 49 Degrees F
The total running time per day is:
64 Minutes
 Mohammad Shams,
HEAT EXCHANGER Seyed Alireza Tabatabaei,
Roozbeh Hojatpanah,

DESIGN Siavash Farahmand,

Shahriar Ahmadi Ghoohaki

Department of Mechanical Engineering, IUPUI

ME 414 Thermal-Fluid Systems Design
Fall 2010, Professor John Toksoy
Design Parameters
Process Fluid
Water

Inlet
45C
Outlet 25C

City Water
Inlet 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 Exchanger overall weight- 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 Shell Side Heat Transfer Parameters
Number of Tubes, N 4169 Shell ID 0.5398 m
Number of Passes 1 Shell Cross Sectional Area 0.2289 m2
Tubes OD 0.0063 m Shell Flow Area 0.1059 m2
Tubes ID 0.0054 m Shell Equivalent Diameter 0.0046 m
Tube Length, L 4.4000 m Mass Velocity, G 1028.84 kg/m2.s
Tube Pitch, PT 0.0079 m Heat Transfer Coefficient, h 4419.42 W/m2.C
Heat Transfer Coefficient, h 4158.44 W/m2.C

Overall Heat Transfer Coefficient

U (Tube outside Area) 1739.11 W/m2.C HE Pressure Drop
Heat Transfer Rate Shell Side P 85606.84 Pa
Desired Heat Transfer Rate 5106273.07 W Tube Side P 8115.88 Pa
Calculated Heat Transfer Rate 5133356.91 W Heat Exchanger Weight
Difference -27083.84 W Total Weight 1362.78 kg
Desired - To - Calculated Ratio 0.99
 Adjusted Optimized Results

Tube Side Heat Transfer Parameters Shell Side Heat Transfer Parameters
Number of Tubes, N 3881 Shell ID 0.5462 m
Number of Passes 1 Shell Cross Sectional Area 0.2343 m2
Tubes OD 0.0062 m Shell Flow Area 0.1084 m2
Tubes ID 0.0053 m Shell Equivalent Diameter 0.0045 m
Tube Length, L 4.2759 m Mass Velocity, G 1006.65 kg/m2*s
Tube Pitch, PT 0.0077 m Heat Transfer Coefficient, h 4383.64 W/m2*C
Heat Transfer Coefficient, h 4087.62 W/m2*C

Overall Heat Transfer Coefficient HE Pressure Drop

U (Tube outside Area) 1715.16 W/m2*C Shell Side P 85674.36 Pa
Heat Transfer Rate Tube Side P 7956.80 Pa
Desired Heat Transfer Rate 5106273.07 W Heat Exchanger Weight
Calculated Heat Transfer Rate 5163877.58 W
Total Weight 1360.46 kg
Difference -57604.51 W
Desired - To - Calculated Ratio 0.99
Questions