Natural Gas Consumption 1

ME 414 HVAC Project

Michael Stark

Joshua Keith

Billy Burdette

Brandon Mullen

Joseph Listerman

CUMMINS CONFIDENTIAL 2

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

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

CUMMINS CONFIDENTIAL

SIPOC Process Map

ME 414 – 6S Approach 6

Supplier

Homeowner

Homeowner

Insulation Contractor

Homeowner

Homeowner

Mite - E - Ducts

Furnace

Gas bill

Temperature Sensor

Prof. Toksoy

Temperature Sensor

Homeowner

Homeowner

Input

Set desired temperature

Remove old filter, insert new filter

Add insulation to walls and ceiling, increase R value

Caulking, replace door and window seals

Set desired temperatures and times

Vacuum duct work

Thermostat turns furnace on

Fuel burning

Record time furnace is running

A file

Voltage

Hot water usage, shower, cleaning, washer, dishwasher...

Turn the stove knob on

Process

Adjust Thermostat

Change furnace filter

Improve Insulation

Seal doors and windows

Program temperature cycling

Clean ducts

Burning Gas

Measure 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/off

Reduced resistance to air flow

Decreased heat loss

Decreased heat loss

Moderate gas consumption during off-peak hours

Improved air flow

Fuel is consumed

Heat 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

Amount of fuel volume not used for heating

Customer

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

Homeowner

CUMMINS CONFIDENTIAL 8

Flow-Chart Process Map

ME 414 – 6S Approach

CUMMINS CONFIDENTIAL 9

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 figureME 414 – 6S Approach

CUMMINS CONFIDENTIAL 10

Critical Parameter Map

ME 414 – 6S Approach

CUMMINS CONFIDENTIAL 11

Critical Parameter Map Continued

ME 414 – 6S Approach

CUMMINS CONFIDENTIALThis is a Header 12

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

CUMMINS CONFIDENTIAL 13

House Layout

ME 414 – 6S Approach

Basement Floor

First Floor

Second Floor

CUMMINS CONFIDENTIAL 16

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 Approach

CUMMINS CONFIDENTIAL 17

Heat Transfer Surfaces

The chart below displays the percent total area where heat loss occurs for three primary types of surfaces.

ME 414 – 6S Approach

92%

7%1%

Areas in House

WallsWindowsDoors

CUMMINS CONFIDENTIAL 18

HDD Calculated vs. Published

ME 414 – 6S Approach

25 30 35 40 45 50 550

10

20

30

40

50

60

f(x) = 0.939770506589167 x + 1.97304204038683R² = 0.990190778150552

HDD Calculated vs. Published

Calculated HDD (°C)

Published H

DD

(°C

)

CUMMINS CONFIDENTIAL 21

Calculated Data

ME 414 – 6S Approach

25 30 35 40 45 50 550.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

f(x) = 0.0685639124116851 x + 0.418724708122463R² = 0.586995928816416

Furnace On Time vs. Calculated HDD

Calculated HDD (°C)

Furn

ace O

n T

ime (

hours

)

CUMMINS CONFIDENTIAL 22

Calculated Data

ME 414 – 6S Approach

25 30 35 40 45 50 550.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

f(x) = 0.0714691011235955 x + 0.332847913322632R² = 0.568859861417215

Furnace On Time vs. Published HDD

Published HDD (°C)

Furn

ace O

n T

ime (

hours

)

CUMMINS CONFIDENTIAL 24

Calculated Data

ME 414 – 6S Approach

22-Jan 28-Jan 29-Jan 3-Feb 4-Feb 5-Feb 6-Feb0

10

20

30

40

50

60

70

Number of On - Off Cycles

Calculated # of On - Off cycles Plotted # of On - Off cycles

CUMMINS CONFIDENTIAL 34

Total Heat Loss on Sampled Days

ME 414 – 6S Approach

40200 40206 40207 40212 40213 40214 40215

0

2000

4000

6000

8000

10000

12000

14000

Total heat loss (watts) per day

Data

CUMMINS CONFIDENTIAL 35

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 Approach