Environmental Product Declaration According to ISO 14025

Transcription

1 According to ISO Trane Centrifugal Chiller 2500 Ton Trane Declaration number EPD-TRA E Institute for Construction and Environment

2 Summary Environmental Product-Declaration Institute for Construction and Environment Program holder Trane 3600 Pammel Creek Rd La Crosse, WI USA Declaration holder EPD-TRA E Declared building product This declaration is an environmental product declaration according to ISO and describes the specific environmental impacts of the mentioned centrifugal chiller. It is supposed to foster the sustainable development of environmentally and health friendly construction. All relevant environmental data is contained in this validated declaration. Declaration number Declared Building Products The declaration is based on the PCR document, Water-cooled chillers, year This validated declaration entitles the usage of the label of the Institute for Construction and Environment. This exclusively applies to the mentioned products, three years from the date of issue. The declaration holder is liable for the basic information and verifications. Validity The declaration is complete and contains in detailed form: - Product definition - Raw materials - Description of product manufacture - Results of the life cycle assessment Content of the declaration July 1, 2011 Date of Issue Signatures Prof. Dr.-Ing. Horst J. Bossenmayer (President of the Institute for Construction and Environment) This declaration, and the rules on which it is based, have been verified by the independent Advisory Board (SVA) according to ISO Verification of the Declaration Signatures Prof. Dr.-Ing. Hans-Wolf Reinhardt (Chairman of the independent advisory board) Dr. Eva Schmincke (Verifier appointed by the Advisory Board)

3 Summary Environmental Product-Declaration A centrifugal chiller is a machine that removes heat from a liquid via a vapor-compression cycle. The cooled liquid can then be circulated through a heat exchanger to cool air or equipment as required. The chiller utilizes the vapor-compression cycle to chill water and reject the heat collected from the chilled water plus the heat from the compressor to a second water loop cooled by a cooling tower. Product description The function of this chiller is to provide chilled water for cooling a commercial building. The LCA is performed according to ISO corresponding to the requirements of the guidelines concerning Type III declarations of the Institute for Construction and Environment. Specific industrial data from Trane as well as data from the data base GaBi 4 is used as data basis. The LCA comprises raw material and energy consumption, raw material transports and the actual production phase of Trane centrifugal chillers, as well as its recycling at the end of the life cycle. The LCA applies to the Trane CenTraVac family of chillers (model numbers CVHE, CVHF, CDHF, CVHG, and CDHG) that are manufactured in La Crosse, Wisconsin, U.S.A. Trane centrifugal chiller Applications Scope of the LCA Results of the LCA Parameter Unit per ton chilling capacity Product Primary energy, non-renewable [MJ] 944, Primary energy, renewable [MJ] 50, Global Warming Potential (GWP 100 year) [kg CO 2 -eqv.] 63, Ozone Depletion Potential (ODP) [kg R11-eqv.] 7.08E 03 Acidification Potential (AP) [kg SO 2 -eqv.] Eutrophication Potential (EP) [kg PO 3-4 -eqv.] Photochemical Ozone Creation Potential (POCP) [kg C 2 H 4 -eqv.] Issued by: PE INTERNATIONAL, Leinfelden-Echterdingen In cooperation with Trane Tests and verification according to PCR, including test standard and test date. Evidence and verifications

4 CenTraVac Chiller Page 4 Scope of validity This EPD is valid for the Trane CenTraVac family of chillers (model numbers CVHE, CVHF, CDHF, CVHG, and CDHG) that are manufactured in La Crosse, Wisconsin, U.S.A. 1 Product definition Product definition Application Placing on the market/ Codes of practice Delivery status, properties A centrifugal chiller is a machine that removes heat from a liquid via a vaporcompression cycle. The cooled liquid can then be circulated through a heat exchanger to cool air or equipment as required. The chiller utilizes the vaporcompression cycle to chill water and reject the heat collected from the chilled water plus the heat from the compressor to a second water loop cooled by a cooling tower. The function of this chiller is to provide chilled water for cooling a commercial building. The rating and testing of chillers used in comfort cooling applications are standardised according to ARI Standard 550/ , Performance Rating of Water Chilling Packages Using the Vapor Compression Cycle. The dimensions of the declared product are: width: /16 inches; length: 299 inches; height: 134 3/8 inches. Technical properties The chilling capacity of this product is 2500 tons. The energy efficiency in the table below is calculated based on different combinations of load % and Entering Condenser Water Temperature (ECWT), as described in the background report. 65 F 65 F 75 F 85 F For constant-speed started chillers, the evaporator s pressure drop is feet of water, and the condenser s pressure drop is 9.76 ft of water. 2 Basic materials For variable-speed started chillers, the evaporator s pressure drop is feet of water and the condenser s pressure drop is ft of water. Declaration of basic materials The chiller assembly is broken into major assemblies as described below. Total Lbs Compressor 29,157 Compressor Install 5,070 Condenser 25,265 Controls 31 Economizer 668 Evaporator Tubes 16,453 Motors 363 Oil Tank 511 Purge 1,290 Shell 1,281 Unit Assembly ,008 The raw materials used in these assemblies are shown in the following figure.

5 CenTraVac Chiller Page 5 Auxiliary substances / additives Material explanation Raw material extraction and origin Availability of raw materials The chiller requires an initial charge of 1.6 lbs R-123 coolant per ton of chilling capacity for a total of 4000 lbs. Additional coolant recharges are also required at a maximum of 0.5% per year (20 lbs / year). The chiller heat exchangers are primarily made of carbon steel sheet with copper tubes used for heat transfer. The compressor is made of cast gray iron components that form the enclosure, with aluminum cast internal components and an electrical motor made from copper wire, electrolytic steel stampings and a steel shaft. The major components of the chiller are metals and metal parts that come from the global metal markets. Global averages are used for input materials where possible. All the materials used in the manufacture of this chiller are available in the earth s crust. None of the metals or scrap sources are rare or greatly depleted. 3 Product manufacturing Manufacturing process 4 Product installation The manufacturing of centrifugal chillers in La Crosse, Wisconsin, uses lean Six Sigma manufacturing practices to provide a full range of products from 140 to 4000 tons. All production components arrive when needed (including raw casting, plate steel, copper tubing and labor) to reduce inventory and allow a smaller manufacturing footprint, better aligning and minimizing necessary resources to meet customer requirements, including transportation costs and waste, and obsolesce of materials. Plate steel is flame-cut, rolled, drilled, and sub-arc welded into shells and waterboxes. Gray-iron and aluminum castings are machined and assembled into a compressor. These primary components, along with subassemblies (i.e. starters, purges, controls, lubrication system), are assembled using a combination of welding, brazing, bolting, and testing to create the CenTraVac centrifugal chiller. Installation Environmental protection Handling recommendations for refrigerants can be found in product and application literature, brochures and data sheets provided directly by suppliers of available from the internet; www2.dupont.com/dupont_home/en_us/index.html During the entire production process, extra measures are taken to minimize the unintentional release of halogenated refrigerants. These measures are consistent

6 CenTraVac Chiller Page 6 Packaging with those identified in ANSI/ASHRAE Standard , Reducing Release of Halogenated Refrigerants from Refrigeration and Air-Conditioning Equipment and Systems. The chiller is packaged in a single, large heat-shrink recyclable plastic bag for shipping to protect it from damage due to environmental conditions. Packaging is excluded from the scope of the LCA based on the mass cut-off rules. 5 Condition when in use Use stage Energy Consumption Energy consumption of the chiller during its reference service life depends on the application and site-specific use phase parameters. In order to determine average annual chiller energy usage for a given region or location, a life-cycle program was utilized to determine average weighting factors for specific buckets of performance. The four buckets, or performance bins, being utilized are those defined by AHRI Standard 550/ and include 100% load at 85 F entering condenser water, 75% load at 75 F entering condenser water, 50% load at 65 F entering condenser water, and 25% load at 75 F entering condenser water. In addition to the percentages, the annual hours of operation were determined. The software that was used to obtain the above mentioned values has been tested in compliance with ANSI/ASHRAE Standard This procedure has been developed to determine the average energy usage impact for a given location, by manufacturer. The values resulting from the calculation are not intended to reflect actual energy usage for specific applications. The intent is to provide the means of having a global and universal method of determined average energy usage of chillers by manufacturer. For specific energy usage and life-cycle evaluation, a complete analysis must be completed for each and every application. 65 F 65 F 75 F 85 F Hours of Operation Consumption over 25 yr life [kwh] Atlanta ,675,754 Bangkok ,373,161 Beijing ,506,075 Berlin ,755,656 Boston ,406,010 Buenos Aires ,505,941 Cairo ,261,453 Cancun ,546,816 Capetown ,857,446 Caracas ,198,438 Chicago ,604,788 Dallas ,022,640 Denver ,010,961 Dubai ,977,795 Hanoi ,392,528 Ho Chi Minh ,969,063 Hong Kong ,791,930 Houston ,881,395

7 CenTraVac Chiller Page 7 Jerusalem ,411,700 Kansas City ,559,472 London ,628,462 Los Angeles ,638,635 Madrid ,230,525 Manila ,464,803 Melbourne ,588,375 Mexico City ,706,047 Miami ,722,813 Minneapolis ,051,938 Moscow ,203,698 Mumbai ,743,750 New Delhi ,866,859 Ottawa ,776,860 Paris ,711,133 Perth ,106,713 Phoenix ,904,185 Raleigh ,486,234 Riyadh ,376,966 Rome ,271,921 San Diego ,699,000 San Francisco ,384,060 San Juan ,956,147 Sao Paulo ,937,638 Seattle ,039,309 Seoul ,554,078 Shanghai ,916,198 Singapore ,125,000 Sydney ,549,497 Taipei ,817,894 Tokyo ,550,232 Toronto ,655,933 Vancouver ,246,981 Venice ,019,555 Vienna ,232,625 Warsaw ,562,090 Washington DC ,404,033

8 CenTraVac Chiller Page 8 Environment health effects Maintenance Reference Service Life During the entire production process, extra measures are taken to minimize the unintentional release of halogenated refrigerants. These measures are consistent with those identified in ANSI/ASHRAE Standard , Reducing Release of Halogenated Refrigerants from Refrigeration and Air-Conditioning Equipment and Systems. Maintenance for this product is described in the CenTraVac Annual Inspection Check List and Report, which can be provided upon request. The checklist covers aspects relating to the compressor motor, starter, oil sump, condenser, control circuits, leak test chiller, and the purge unit. The reference service life (RSL) is 25 years in an outdoor application. 6 Singular effects Fire Product is inflammable. Water Chiller designed with NEMA 4 construction to prevent failure of components from water contact. 7 End of life phase Reuse Subsequent use Closed-loop recycling The chiller is not reused. N/A Metal components of the chiller can be recycled into other systems. Scrap at end of life is modelled as looping back to fill the demand for scrap in the incoming raw material manufacture. Credit is applied to the environmental profile of surplus scrap based on the average value of that scrap. Open-loop recycling Disposal Scrap at end of life is modelled as looping back to fill the demand for scrap in the incoming raw material manufacture. Credit is applied to the environmental profile of surplus scrap based on the value of scrap methodology described below. Product disposal is left to the owner s discretion.

9 CenTraVac Chiller Page 9 8 Life cycle assessment 8.1 Information on system definition and modeling of the life cycle Declared Unit System boundaries The declared unit refers to one ton chilling capacity for a 2500-ton centrifugal chiller. Assumptions and estimations Cut-off criteria Transports The product mix presented is representative of the product range of the plant. For the life cycle assessment, a single product has been modeled to represent the product family. Regarding power supply, the energy carriers and energy sources used for the production site have been considered. All process waste resulting from production and finishing is recycled internally. The end-of-life scenario has been assumed as recycling and has been modeled based on an elementary analysis, according to the average composition of the products. If a flow is less than 1% of the cumulative mass of all the inputs and outputs of the Life Cycle Inventory model, it may be excluded, provided its environmental relevance is not a concern. If a flow meets the above criteria for exclusion, yet may have a significant environmental impact, it is evaluated with proxies identified by chemical and material experts within PE. If the proxy for an excluded material has a significant contribution to the overall Life Cycle Impact Assessment (5% or more of any impact category), more information is collected and evaluated in the system. The major components of the chiller are metals and metal parts that arrive at the Trane facility via truck and rail. Approximately 80% of incoming parts and materials arrive by truck, the remainder come by rail. The average distances for inbound parts by truck and rail are miles and miles, respectively.

10 CenTraVac Chiller Page 10 Period under consideration Background data Data quality Allocation Information on use stage Choice of the endof-life scenario The chiller production is modeled based on a 12-month average from Q Q for the site involved in data collection. For life cycle modeling, the GaBi 4 Software System for Life Cycle Engineering was used /GaBi 2006/. All background data sets relevant to production and disposal were taken from the GaBi 4 software. The data was collected under consistent time and methodological boundary conditions. All data used is less than 5 years old. Steel, aluminum, cast iron, and copper scrap generated during manufacturing and at End-of-Life were considered valuable co-products, and were addressed with system expansion. To be consistent with the Worldsteel dataset for steel plates, the scrap steel was given a credit based on the Value of Scrap model as described in a study of recycling methodologies. This model is also included upstream in the production of other steel parts, which includes scrap input, and is consistent throughout the study. Aluminum, cast iron, and copper scrap were also given credits based on the production of primary metal, less any energy and materials required for remelting / alloying of these secondary materials. This approach was chosen to ensure that both the use of post-consumer scrap and high collection rates are encouraged. Emissions of refrigerant during the use phase are included in this EPD. Also, emissions related to the generation and distribution of electricity for product use is included. The product is assumed to be disassembled and the components separated by material type. Credits are applied for scrap steel, aluminum, cast iron, and copper. Credits Credits are applied for surplus scrap steel, aluminum, cast iron, and copper generated during manufacture and at end of life. The credits are calculated based on the Value of Scrap methodology used in the creation of upstream datasets.

11 8.2 LCA Results Trane Centrifugal Chiller Product Stage Construction Process stage Use stage / operation Use stage / maintenance End Of Life Credits Unit per ton chilling capacity Raw material supply, Transport, Manufacturing Transport Constructioninstallation Process Use Maintenance incl. Transport Repair, Replacement, Refurbishment, incl. Transport Transport Re use/recycling Disposal Credits Primary energy from non renewable resources Primary energy from renewable resources [MJ] , [MJ] , Total mass of Resources (TMR) ADP excluding resources [kg] 1, , [kg Sb eq.] 5.63E E E 05 Mass of secondary material Fresh water utilization [kg] [m 3 ] 475, ,521, , Global Warming Potential Ozone Depletion Potential Acidification Potential Eutrophication Potential Photochemical Ozone Creation Potential [kg CO 2 eq.] [kg R11 eq.] [kg SO 2 eq.] [kg Phosphate eq.] [kg Ethylene eq.] , E E E E E E E E E E E E 03 Materials for recycling Hazardous waste to final disposal Non hazardous waste to final disposal [kg] 4.14E E E+01 [kg] 1.19E E E 01 [kg] 1.01E E E 01 Radioactive waste [kg] 1.25E E E+00

12 CenTraVac Chiller Page 12 Contributing Factors The graph below shows environmental impacts split out for 25 years of service life. The electricity demand during use dwarfs all other impacts. Interpretation Because the Use Phase dominates all other impacts by a factor of more than 1000, selected impact categories are shown below without this life cycle phase. The graph below shows that manufacturing energy dominates the cradle-to-gate impacts of the chiller s life cycle, followed by upstream production of steel and copper. In the graph below, the raw materials are broken out by type (1a 1f), followed by Transport (2), Manufacturing energy (3), and End of Life credits (5). Transport plays a minimal impact, but the material credits at End-of-Life are substantial. When calculating the credits for recycling of metals after the Use stage, it was assumed that Masdar, being a zero waste city, would reclaim all of the steel, aluminum, iron, and copper. Other materials are assumed to be reused in other product systems, but no credit is applied.

13 CenTraVac Chiller Page 13 9 Evidence The manufacturer presents the relevant test certificates to IBU. 10 PCR-document and verification This declaration is based on the Product Category Rules Water Cooled Chillers Review of the PCR-Documents by the Committee of Experts. Chairman of the Committee of Experts: Prof. Dr.-Ing. Hans-Wolf Reinhardt (Stuttgart University, IWB) Independent verification of the declaration according to ISO 14025: internal external Validation of the declaration: Dr. Eva Schmincke 11 References /Institut Bauen und Umwelt/ /GaBi / Leitfaden für die Formulierung der produktgruppen-spezifischen Anforderungen der Umwelt-Produktdeklarationen (Typ III) für Bauprodukte, GaBi 4: Software und Datenbank zur Ganzheitlichen Bilanzierung. LBP, Universität Stuttgart und PE International, Standards and laws /ISO 14025/ /ISO 14040/ /ISO 14044/ ISO 14025: , Umweltkennzeichnungen und -deklarationen - Typ III Umweltdeklarationen - Grundsätze und Verfahren (ISO 14025:2006); Text Deutsch und Englisch ISO 14040: , Umweltmanagement - Ökobilanz - Grundsätze und Rahmenbedingungen (ISO 14040:2006); Deutsche und Englische Fassung EN ISO 14040:2006 ISO 14044: , Umweltmanagement - Ökobilanz - Anforderungen und Anleitungen (ISO 14044:2006); Deutsche und Englische Fassung EN ISO 14044:2006

14 Publisher: Institute for Construction and Environment (IBU) Rheinufer Königswinter Germany Tel.: +49 (0) Fax: +49 (0) info@bau-umwelt.com Internet: Layout: PE INTERNATIONAL Illustration credits: Trane Trane 3600 Pammel Creek Rd La Crosse, WI USA