1. Harley-Davidson Museum Milwaukee, WI. Jonathan Rumbaugh, BAE/MAE Mechanical Option Advisor: Dr. William Bahnfleth

2. P ROJECT S PONSORS

3. P RESENTATION O UTLINE Project Background Existing Conditions Thesis Goals Structural Breadth: Thermal Bridging Mechanical Depth: Air vs. Water Electrical Breadth CHP Feasibility Conclusion Jonathan RumbaughHarley-Davidson MuseumMechanical Option P ROJECT S PONSORS

4. P ROJECT B ACKGROUND Jonathan RumbaughHarley-Davidson MuseumMechanical Option Project Background Building Statistics Location & Layout Existing Conditions Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion Size (Total Square Feet): 130,000 Number Stories Above grade: 3 Construction timeline : April 2005 – May 2008 Overall Project Cost: $75 million B UILDING S TATISTICS Guggenheim by Frank Gehry 257,000 square feet $100 million Wordpress.com

5. Project Background Building Statistics Location & Layout Existing Conditions Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion Jonathan RumbaughHarley-Davidson MuseumMechanical Option P ROJECT B ACKGROUND

6. E XISTING C ONDITIONS Project Background Existing Conditions Mechanical Design Energy Model Emissions Comparison Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion M ECHANICAL D ESIGN Two Roof Mounted 300 Ton Air-cooled Rotary Screw Chillers Four 2000 MBH Sealed Combustion Condensing Boilers Variable Primary Flow 11 Air Handling Units 2 4 5 Jonathan RumbaughHarley-Davidson MuseumMechanical Option

7. E XISTING C ONDITIONS Project Background Existing Conditions Mechanical Design Energy Model Emissions Comparison Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion E NERGY M ODEL Jonathan RumbaughHarley-Davidson MuseumMechanical Option $0.10 / kWh Electricity $0.80 / Therm Natural Gas

8. E XISTING C ONDITIONS Project Background Existing Conditions Mechanical Design Energy Model Emissions Comparison Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion E MISSIONS Jonathan RumbaughHarley-Davidson MuseumMechanical Option Calculations use factors from the Regional Grid emissions Factors 2007. table B-10

9. E XISTING C ONDITIONS Project Background Existing Conditions Mechanical Design Energy Model Emissions Comparison Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion E MISSIONS Jonathan RumbaughHarley-Davidson MuseumMechanical Option Calculations use factors from the Regional Grid emissions Factors 2007. table B-10 9 Million lbs. of C0 2e / year 867 acres

10. E XISTING C ONDITIONS Project Background Existing Conditions Mechanical Design Energy Model Emissions Comparison Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion C OMPARISON Jonathan RumbaughHarley-Davidson MuseumMechanical Option C ONCLUSION Energy Model is an accurate representation of the energy consumption of the facility

11. T HESIS G OALS Project Background Existing Conditions Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion Jonathan RumbaughHarley-Davidson MuseumMechanical Option G OALS P ROPOSAL Reduce Emissions Reduce Energy Consumption Reduce Operating cost Emissions Operating Cost Energy Consumption Decrease Thermal Loads Through Envelope Increase Efficiency of Chilled Water Production Become Energy Independent From Grid

12. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL B RIDGING Location of thermal break N Jonathan RumbaughHarley-Davidson MuseumMechanical Option

13. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL A NALYSIS Jonathan RumbaughHarley-Davidson MuseumMechanical Option

14. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL A NALYSIS Jonathan RumbaughHarley-Davidson MuseumMechanical Option

15. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL A NALYSIS Jonathan RumbaughHarley-Davidson MuseumMechanical Option

16. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL A NALYSIS Jonathan RumbaughHarley-Davidson MuseumMechanical Option

17. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL A NALYSIS 8760 hr. study Total: 272,407.12 Watts per year Jonathan RumbaughHarley-Davidson MuseumMechanical Option

18. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL A NALYSIS T2T2 T1T1 8760 hr. study Total: 108.19 Watts per year Lowest indoor temp = 69 o F Savings: $1,271.19 / year [Main gallery] For a simple payback of 5 years Each Thermal Break = $653 Jonathan RumbaughHarley-Davidson MuseumMechanical Option

19. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion T HERMAL A NALYSIS Jonathan RumbaughHarley-Davidson MuseumMechanical Option

20. S TRUCTURAL B READTH Project Background Thesis Goals Existing Conditions Structural Breadth Thermal Analysis Structural Analysis Mechanical Depth Electrical Breadth Conclusion S TRUCTURAL A NALYSIS Location of thermal break N MemberForceAllowableActualOK? BeamBending Moment 64.12 ft kips 18.5 ft kips Yes BeamShear79.1 kips3.7 kipsYes GirderBending Moment 3723 ft kips 686Yes GirderShear886 kips40.05 kipsYes GirderLive Load Deflection 3.4”2.75”Yes GirderTotal Deflection 6.85”6.6”Yes ColumnLoad355 kips50Yes Thermal Break Shear13,400 psi2.24 psiYes Jonathan RumbaughHarley-Davidson MuseumMechanical Option

21. P ROJECT D EPTH Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Carrier Two 300 Ton Air Cooled Chillers EER 9.4 A IR VS. W ATER Carrier Two 300 Ton Water Cooled Chillers COP 5.9 EPA Jonathan RumbaughHarley-Davidson MuseumMechanical Option Carrier

22. P ROJECT D EPTH A IR VS. W ATER Additional Water: 2,500 1000gal Cost : $5,500.00 / year Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Jonathan RumbaughHarley-Davidson MuseumMechanical Option Capital: -$42,850

23. P ROJECT D EPTH A IR VS. W ATER 30 Year LCC Existing Air-Cooled System: $4,045,288.09 Alternative 2; Water-Cooled System: $3,861,471.04 Savings: $183,817.05 Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Jonathan RumbaughHarley-Davidson MuseumMechanical Option Capital: -$42,850

24. P ROJECT D EPTH C OOLING TOWER VS. R IVER W ATER Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Cold Water Temp = 0.739*WB + 27.35 Supply Return Jonathan RumbaughHarley-Davidson MuseumMechanical Option

25. P ROJECT D EPTH Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Supply Return C OOLING TOWER VS. R IVER W ATER Jonathan RumbaughHarley-Davidson MuseumMechanical Option

26. P ROJECT D EPTH C OOLING TOWER VS. R IVER W ATER Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Jonathan RumbaughHarley-Davidson MuseumMechanical Option Capital: +$104,255

27. P ROJECT D EPTH C OOLING TOWER VS. R IVER W ATER Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Simple Payback: 2.8 years Discount payback : 3.0 years 30 Year LCC Alternative 2; Cooling Tower System: $3,861,471.04 Alternative 3; River Water System: $3,641,264.61 Savings: $220,206.43 Jonathan RumbaughHarley-Davidson MuseumMechanical Option Capital: +$104,255

28. P ROJECT D EPTH C ONCLUSION Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Air vs. Water Cooling Tower vs. River Water Conclusion Electrical Breadth Conclusion Jonathan RumbaughHarley-Davidson MuseumMechanical Option Air-Cooled vs. Water-Cooled with River Water Capital cost increased 10% [$61,400.00] Annual operating cost reduced by 14% [$21,732.00] 30 year LCC reduced 10% [$389,986.00] Simple payback 3 years

29. E LECTRICAL B READTH CHP F EASIBILITY Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Electrical Breadth CHP Feasibility Conclusion TRANE Spark Gap Electric Cost: $0.10/kWh = $29.30/MMBTU Gas Cost: : $0.80/therm = $8.00/MMBTU 1 : 3.7 Ratio, 1 : 4 [rule of thumb] Jonathan RumbaughHarley-Davidson MuseumMechanical Option

30. CHP F EASIBILITY Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Electrical Breadth CHP Feasibility Conclusion Thermal-to-Electric Ratio = 0.74 Recommended: 373 kWe Gas Engine E LECTRICAL B READTH Jonathan RumbaughHarley-Davidson MuseumMechanical Option

31. CHP C ONCLUSION Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Electrical Breadth CHP Feasibility Conclusion Additional Cost $564,000 Generation Cost $0.088 /kWh 1.2 cents less than purchased Total Savings: $140,000 /year Simple Payback: 4.04 Years CO 2 reduction of 62% E LECTRICAL B READTH Jonathan RumbaughHarley-Davidson MuseumMechanical Option

32. Project Background Thesis Goals Existing Conditions Structural Breadth Mechanical Depth Electrical Breadth Conclusion C ONCLUSION Savings: $1,271.19 / year [Main gallery] Air-CooledCooling TowerRiver Water Capital$550,000.00$507,145.00$611,400.00 Simple Payback--2.8 years 30 Year LCC Savings-$184,817.00$389,986.93 Jonathan RumbaughHarley-Davidson MuseumMechanical Option Total $160,000 Annually 4 Year Payback 65% Reduction of CO 2 ++ =

33. Q UESTIONS ? Project Background Existing Conditions Thesis Goals Structural Breadth Mechanical Depth Electrical Breadth Conclusion T HANK Y OU HGA Kevin Pope, P.E.Associate Vice President, HGA Jeff Harris, P.E. Director of Mechanical Engineering, HGA, Penn State Alumni Steve Mettlach Mechanical Engineer, HGA Harley-Davidson Joyce Koker, P.E. Harley-Davidson Museum Penn State Dr. William Bahnfleth Faculty Advisor Dr. Jelena Srebric AE Mechanical Professor Dr. James Freihaut AE Mechanical Associate Professor Mr. David H. TranAE 5 th Year Structural, BAE/MS Family and friends for their support

34. Air-Cooled ElecWaterGas kWh1000galtherms Elec 2,168,082.30 Air Side 569,425.50 Water Side 683,862.00 Hot water 12,833.20 74.90 37,736.30 total 3,434,203.00 74.90 37,736.30 Water-Cooled with Cooling Tower ElecWaterGas kWh1000galtherms Elec 2,168,082.30 Air Side 569,425.50 Water Side 557,153.20 2,505.10 Hot water 12,833.20 74.90 37,736.30 total 3,307,494.20 2,580.00 37,736.30 Water Cooled with River ElecWaterGas kWh1000galtherms Elec 2,168,082.30 Air Side 569,425.50 Water Side 459,295.80 Hot water 12,833.20 74.90 37,736.30 total 3,209,636.80 74.90 37,736.30