Plastics factory load assumptions

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Dear List,
I am looking for some EUI information to use in determining reasonable
process loads.

Currently I have used 2 W /sqft for a simple internal equipment object. The
assumption seems reasonable, but I simply guessed- so am hopeful to find
some reference documentation to base my assumptions on. Alternatively the
design team and I have discussed measuring the equipment at peak or average
load. If we where to measure, it would be great to have some guidelines for
such large equipment.. (school bus size injection plastic molding)

Here is the comment I got from a LEED reviewer:
*It is not recommended that you use exactly 25% as the value for process
loads. You should estimate, as closely as possible, what your actual
process loads will be, and then use those estimates. Following is an
excerpt of commonly used review text that GBCI uses to address this very
issue, "The unregulated receptacle and process energy should not be
arbitrarily set to 25% of the total baseline building cost, but should
reflect the actual process loads in the appropriate spaces as required by
ASHRAE 90.1-2007 Table G3.1.1(a) and G3.1.12. Revise the proposed and
baseline building energy models as necessary to reflect the actual
unregulated inputs (such as receptacle loads, kitchen loads, elevator
loads, etc.) in the appropriate spaces. In addition, revise the
Supplemental Table 1.4 reflecting the changes. If the process cost is below
25% of the Baseline energy cost after making any necessary changes, provide
an additional narrative justification for the low process cost." Note that
the 25% process load minimum included in the **LEED Reference Guide is not
a requirement. The process loads should be modeled as closely as possible
to the actual process loads. If process loads are significantly less than
25% of the building's total energy loads, then a narrative should be
provided to address how process loads were determined.*

Also, I have been asked to do an exceptional calculation for the highly
efficient factory equipment, however the LEED reviewer wants the
nameplate capacity to be the same. This would not permit me to use the
method I had previously- the simple internal equipment with
latent sensible split, then radiant convective split. Also if we measure
the actual equipment then how would we compare to reference equipment..

Here is the comment from another LEED reviewer that my client contacted:
*The energy efficiency measures for [MEASURE DESCRIPTIONS] should be
modeled using the Exceptional Calculation methodology. A narrative should
describe all Baseline and Proposed case assumptions included for this
measure as well as the calculation methodology used to determine the
projected savings. The narrative and energy savings should be reported
separately from the other efficiency measures in Section 1.7 - Table
EAp2-7. The Baseline case description should verify that the manufacturing
equipment installed is not standard practice for a similar newly
constructed facility by referencing a recently published document
(published within five years of the project registration date), utility
program that incentivizes the equipment installed, or by documenting
systems used to perform the same function in other newly constructed
facilities (three facilities built within the past five years of the
project registration date). The baseline system type described should also
have the same output capacity as the proposed system type modeled.*

So my questions are:

How are factories normally modeled?
How is such large equipment normally modeled?
Are there any published benchmarks to reference?
Are there any guidelines on measuring the performance of such equipment?

Any feedback or ideas are welcome and thanks

* Jeremiah D. Crossett*

Jeremiah Crossett2's picture
Joined: 2012-12-14
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