Hot water coils are common in commercial building HVAC systems. Nevertheless, their design, installation, and control are frequently sub-optimal, with respect to maximizing heat exchange effectiveness and air temperature setpoint control. For example, conditions on-site sometimes lead to coils being installed in parallel flow instead of counter flow configuration, and temperature stratification in the leaving air can lead to control issues. Additionally, low hot water supply temperatures (HWST) of ~120⁰F (49⁰C) are becoming more common with the rise of heat pump and efficiency retrofits. As hot water systems are typically designed for high HWST (160 - 180⁰F, 71 - 82⁰C), lower waterside “delta T” temperature differences (HWST – HWRT) would occur using low HWST in retrofits of conventional hot water heating systems. If buildings retain existing coils for the low-HWST systems common to efficiency retrofits, they will be unable to maintain the same design heat capacity without replacing terminal units. This creates challenges for retrofit projects throughout the industry, and low-HWST designs also present challenges to new construction. We present the background, methods, and findings of an experiment conducted in 2022 at the Price Industries Laboratory in Winnipeg, Canada. In this experiment, we tested multiple VAV HW reheat terminal units across a range of test factors, including VAV box sizes and number of coil rows. The performance of each coil setup was compared at both high and low HWSTs, and at multiple damper positions. We also performed several additional tests to determine the best solutions to common field installation and operation issues and to gauge the impact of varying coil insulation. In addition to tests we ran with stock-manufactured coils, we also ran several tests using coils of our own custom designs, focusing on symmetry and limited circuit count. The intent of these tests was to better understand the factors in VAV HW reheat systems that may be overlooked in typical system design and coil selection processes, especially as parameters such as HWST and water side temperature differences begin to change. Understanding these factors is important to the design and operation of these systems as sub-optimal performance in the terminal unit systems has cascading effects both for retro-fitted low-HWST systems and existing boiler systems. Overall, the results from this experiment serve to inform recommended changes to VAV terminal unit design, selection, and control to improve whole-building performance.

We studied a combination of heating system measures in two large commercial officebuildings in San Francisco (110,000 and 120,000 ft 2 respectively) within a project funded by the California Energy Commission’s Public Interest Efficiency Research program. We retrofitted theexisting heating plants and updated the HVAC controls to ASHRAE Guideline 36-2021 as closely as possible while retaining the existing controller hardware. These measures decreased annual natural gas consumption by about 70 percent while also reducing HVAC electricity consumption. The results reinforce previous work showing significant natural gas reductions in 3 other buildings that underwent full controls retrofits (including controller hardware), and large savings from another 3 buildings that underwent partial controls upgrades. We show that on today’s electricity grid, which is quite dirty during the winter and early morning hours when most heating occurs, the carbon emissions reduction from these measures exceeds the reduction from fully electrifying the existing heating system’s load with today’s air-to-water heat pumps. More importantly, these solutions are mutually beneficial. Acknowledging that we also need to electrify HVAC loads to meet our climate goals, replacing controls first will reduce the size, weight, first cost, and ongoing operating cost of the subsequent heat pump installation requiredto fully electrify, and will make it more feasible to do so. This paper highlights an overlooked opportunity for enormous decarbonization in the existing commercial building stock using a solution that is available, cost effective, and scalable. We should prioritize these measures first,and then electrify, rather than focusing solely on electrification.

Conventional wisdom and standard industry practice is to setback zone temperature setpoints when commercial buildings are unoccupied at night. The HVAC systems then operate in warmup mode to recover zone temperatures prior to the start of occupancy, sometimes with an optimal start algorithm. These strategies were intended to reduce HVAC energy consumption when originally developed decades ago but are due for re-examination given the significant changes in HVAC systems that have since occurred. In particular, the changes currently underway with the movement toward electrification present new design considerations and priorities. Warming up a building as fast as possible may not be the best strategy in terms of energy use, operating cost, or carbon emissions. This article discusses some of the downfalls of conventional morning warmup practices, suggests an improved strategy, and shows the results from a pilot field demonstration test.

Natural gas combustion to serve space heating hot water systems causes approximately one third of large commercial building energy use in California. This project evaluated an innovative set of non-proprietary, cost-effective methods to reduce energy consumption and associated emissions from these systems. The project demonstrated 70% natural gas savings and substantial electricity savings in two large office buildings, yielding total utility cost savings of approximately $110,000 (or $0.5/ft²) per year. The project also conducted detailed studies on distribution losses and boiler efficiency in several buildings; measured performance of key components in laboratory tests; gathered and analyzed data from hundreds of buildings to evaluate actual performance of these systems; and provided a public dataset to inform future retrofits, research, and code development. The research also highlighted characteristics that make a building a good candidate for retrofit so these results can be scaled. Market transformation activities included 10 journal and conference publications, policy recommendations and a design guide. Based on these findings and other recent work, the opportunity for similarly large emissions reductions appears to be common within the existing large commercial building stock. The resources provided by this project can aid stakeholders in achieving California’s goals to decarbonize buildings.