1. Natural Gas Consumption1 ME 414 HVAC Project Michael Stark Joshua Keith Billy Burdette Brandon Mullen Joseph Listerman

2. CUMMINS CONFIDENTIAL2 Develop A Charter Why Statement Business case – What is the project purpose? Reduce cost of heating the studied household Obtain a better understand of the HVAC process and analysis Scope of data and calculations involved

3. CUMMINS CONFIDENTIAL Project Schedule March 24 Process Map Critical Parameter Flow Down (CPM) March 31 Calc heater on time using excel programming Calc heating degree days Establish a relationship between HDD and heater on time April 7 Does the calculated HDD correlate with published HDD What is the heat loss from the house Does it correlate with the heater on time May 5 Complete HVAC house study and report ME 414 – 6S Approach3

4. CUMMINS CONFIDENTIAL Types of Process Maps Detailed Process Map Effectively shows input and outputs Includes parties effected by the process Flow-Chart Process Map Excellent method for visually envisioning a process Visually displays outcomes dependent on situations

5. CUMMINS CONFIDENTIAL Detailed Process Map Text oriented document showing the process involved with the project Positives Shows Supplier, Input, Process, Output, and Customer Allows for direct flow from input and output and the parties responsible for both Negatives Only shows linear correlations, which doesnt show interconnections between units. ME 414 – 6S Approach5

6. CUMMINS CONFIDENTIAL SIPOC Process Map ME 414 – 6S Approach6 Supplier Homeowner Insulation Contractor Homeowner Mite - E - Ducts FurnaceGas billTemperature SensorProf. ToksoyTemperature Sensor Homeowner Input Set desired temperatureRemove old filter, insert new filter Add insulation to walls and ceiling, increase R value Caulking, replace door and window seals Set desired temperatures and timesVacuum duct work Thermostat turns furnace onFuel burningRecord time furnace is runningA fileVoltage Hot water usage, shower, cleaning, washer, dishwasher... Turn the stove knob on Process Adjust ThermostatChange furnace filterImprove Insulation Seal doors and windowsProgram temperature cyclingClean ducts Burning GasMeasure volume of fuel consumed Measure heat generation by furnace Measure heat gen. from other sources Measure Outside Temp. Measure fuel consumption by water heater Measure fuel consumption by stove Output Turn furnace on/offReduced resistance to air flowDecreased heat loss Moderate gas consumption during off-peak hours Improved air flow Fuel is consumedHeat usage in therms Amount of fuel used to maintain inside temperature Contribution of electrical appliances to interior temp. Rate of heat loss due to temperature difference Amount of fuel volume not used for heating Customer Homeowner

7. CUMMINS CONFIDENTIALThis is a Header7 Flow-Chart Process Map Visual aid process map that shows flow of events in a given analysis Positives Shows correlations between units Leads user from start to finish of process Shows multiple outcomes from input Shows relationships between suppliers, processes and customers Negatives Not at detailed as previous process map Doesnt show relationships between suppliers, customers and processes

8. CUMMINS CONFIDENTIAL Flow-Chart Process Map ME 414 – 6S Approach8

9. CUMMINS CONFIDENTIAL Critical Parameter Management Defines energy consumption in household Where energy is distributed in house Shows locations of heat loads in a household Supplemental heat production Allows analysis of heat load paths in the household Shows several different paths in one figure ME 414 – 6S Approach9

10. CUMMINS CONFIDENTIAL Critical Parameter Map ME 414 – 6S Approach10

11. CUMMINS CONFIDENTIAL Critical Parameter Map Continued ME 414 – 6S Approach11

12. CUMMINS CONFIDENTIALThis is a Header12 Measurements Household Measurements Rooms: Dimensions Windows Doors Height Floor Area Furnace on time measurement HVAC register outlet temp Outside Temperature Measured LM34 temperature sensor HIH4000 Humidity sensor LTC1298 A/D converter Measure HVAC Register Outlet Temp

13. CUMMINS CONFIDENTIAL House Layout ME 414 – 6S Approach13 Basement Floor First Floor Second Floor

14. CUMMINS CONFIDENTIAL Household Measurements ME 414 – 6S Approach14

15. CUMMINS CONFIDENTIAL Household Measurements ME 414 – 6S Approach15

16. CUMMINS CONFIDENTIAL Heat Loss Analysis Assumptions Basement floor temperature is assumed to be 55°F Ground temperature data taken from ground chart at right. Basement is an underground room with window wells. Windows are exposed to outdoor temperatures. ME 414 – 6S Approach16

17. CUMMINS CONFIDENTIAL Heat Transfer Surfaces The chart below displays the percent total area where heat loss occurs for three primary types of surfaces. ME 414 – 6S Approach17

18. CUMMINS CONFIDENTIAL HDD Calculated vs. Published ME 414 – 6S Approach18

19. CUMMINS CONFIDENTIAL HDD Calculated vs. Published Strong correlation (99%) between calculated and published HDD. The values calculated in the excel macro are an accurate representation of the time period we examined. The strong correlation indicates our measurement system is accurate and functioning properly. Sources of Error Long of wires to sensors can result in measurement noise. ME 414 – 6S Approach19

20. CUMMINS CONFIDENTIAL Calculated Data Table 1: Basic HVAC Household Calculations ME 414 – 6S Approach20 DATEHDD CALCULATEDHDD PUBLISHED% ERROR Furnace on time (hours) # of on-Off Cycles Calculated # of on-off cycles seen on graph Diff between calculated and seen on graph 22-Jan30.1300.33%1.9629 0 28-Jan49.6483.23%3.9151 0 29-Jan50.3500.60%3.9159 0 3-Feb36.937-0.27%2.4733 0 4-Feb33.935-3.24%2.9548 0 5-Feb32.7322.14%3.5157 0 6-Feb42.3413.07%3.1350 0

21. CUMMINS CONFIDENTIAL Calculated Data ME 414 – 6S Approach21

22. CUMMINS CONFIDENTIAL Calculated Data ME 414 – 6S Approach22

23. CUMMINS CONFIDENTIAL Furnace On Time vs. HDD Furnace On Time vs. Calculated HDD R 2 =0.59 shows poor correlation between furnace on time and calculated hdd. We identified two main causes: Limited number of data points dont accurately represent the entire period. Noise generated by the length of the wire could be causing the Excel macro to malfunction. Furnace On Time vs. Published HDD R 2 =0.57 shows poor correlation between furnace on time and published hdd. Similar correlation for each type of HDD indicates a weak positive linear relationship between HDD and heater on time. This indicates that there are other factors that were not measured that affect heater on time more drastically. ME 414 – 6S Approach23

24. CUMMINS CONFIDENTIAL Calculated Data ME 414 – 6S Approach24

25. CUMMINS CONFIDENTIAL HVAC Excel Macro Changes for Heater on Time Calculations ME 414 – 6S Approach25 January 22 nd January 28 th – January 29 th February 3 rd – February 6 th

26. CUMMINS CONFIDENTIAL HVAC Excel Macro Changes for Heater on Time Contd. ME 414 – 6S Approach26 January 22 nd January 28 th – January 29 th February 3 rd – February 6 th

27. CUMMINS CONFIDENTIAL HVAC Excel Macro Changes for Heater on Time Contd. ME 414 – 6S Approach27

28. CUMMINS CONFIDENTIAL Calculated Data First Floor Calculated Data ME 414 – 6S Approach28

29. CUMMINS CONFIDENTIAL Calculated Data Second Floor Calculated Data ME 414 – 6S Approach29

30. CUMMINS CONFIDENTIAL Calculated Data Basement Calculated Data ME 414 – 6S Approach30

31. CUMMINS CONFIDENTIAL Calculated Data House Total Calculated Data ME 414 – 6S Approach31

32. CUMMINS CONFIDENTIAL Calculated Data Heat Loss was calculated for each side of the house. Area for each wall, window, and door was calculated. Heat loss through each area was calculated based on the areas R-value ME 414 – 6S Approach32

33. CUMMINS CONFIDENTIAL Calculated Data Household Calculated Data ME 414 – 6S Approach33

34. CUMMINS CONFIDENTIAL Total Heat Loss on Sampled Days ME 414 – 6S Approach34

35. CUMMINS CONFIDENTIAL Total Heat Loss over 7 days Percent total heat loss for each of the three primary surfaces in the house. Notice this is not proportional to the total areas where heat transfer occurs. The walls comprised 90% of the heat transfer area, but just over 50% of the total losses. ME 414 – 6S Approach35

36. CUMMINS CONFIDENTIAL Final Thoughts Understanding the relationship of heat loss and materials Cost associated with heat loss Relationship of weather conditions and heat loss Sunlight Location of windows Optimization Windows and doors accounted for only 8% of the total house area, yet contributed to nearly 50% of the house heat losses. We would begin reducing cost by eliminating heat losses from windows and doors. Accomplished by: Window Shading Most heat is transferred by radiation not conduction ME 414 – 6S Approach36