1 Can real energy savings be realized by looking at systems instead of components? Resounding YES....
44
1 Can real energy savings be realized by looking at systems instead of components? Resounding YES. Instead of repairing broken parts determine why they broke. Did they break due to a part failure or were they improperly applied? Does the system operate at design? Obtain the design conditions like Delta T. Obtain the design comfort. Are windows used to obtain comfort. Is energy going up the stack or in the condensate? Are the boilers or chillers cycling? Again if a pump or valve fails why? Do you just repair it or possibly address the cause? We always find proper application saves huge energy. Month/Year Title – Department/Author (Insert > Header and Footer)
1 Can real energy savings be realized by looking at systems instead of components? Resounding YES. Instead of repairing broken parts determine why they
1 Can real energy savings be realized by looking at systems
instead of components? Resounding YES. Instead of repairing broken
parts determine why they broke. Did they break due to a part
failure or were they improperly applied? Does the system operate at
design? Obtain the design conditions like Delta T. Obtain the
design comfort. Are windows used to obtain comfort. Is energy going
up the stack or in the condensate? Are the boilers or chillers
cycling? Again if a pump or valve fails why? Do you just repair it
or possibly address the cause? We always find proper application
saves huge energy. Month/YearTitle Department/Author (Insert >
Header and Footer)
Slide 3
2Month/YearTitle Department/Author (Insert > Header and
Footer) When a component fails its time for the engineer in all of
us to kick in. Weve found that the place to start is looking at the
overall design. Lets say its a hydronic heating system we always
look to the original design was it 20F delta T? Say 180F out
looking for a return of 160F back to the boiler? Are there any
other problems with the same system? Constant replacement of
igniters? Temperature control valve operators fail often. These are
just a couple indicators that the system pumps are over pumping. If
youre over pumping you see: Short pump life.Short Valve Operator
Life. Short Boiler component Life.High Operating expense. Poor
comfort.High Service Calls. Instead of spending $1,000 on component
repair spend the $1,000 on Proper pump application, buy the proper
ECM to address the system.
Slide 4
3 The How and Why ALMA COLLEGE BRANDON SMITH GRANDVALLEY STATE
UNIVERSITY RENCE MEREDITH WAYNE STATE UNIVERSITY DAVE KUFFNER
06/14/2015Systecore Inc Is this system Maintenance? Or is this
Energy Savings? Simply applying proper components 50% reduction in
energy cost No monies from Energy Budget Simple maintenance
cost
Slide 5
ALMA COLLEGE BRANDON SMITH OBVIOUS REASONS STUDENT LIVING
CENTERS NEED A HEATING SYSTEM UPGRADE: WINDOWS OPEN WHEN THE HEAT
IS ON DIFFERENTIAL TEMPERATURE ON THE HEATING SYSTEM IS LESS THAN
10 DEG F PUMP FAILURES, SEALS AND BEARINGS ZONE AND SELF OP CONTROL
VALVES FAILING AND MAKING NOISE SOLUTIONS FOR THE LIVING CENTERS:
CONTROL THE HEATING LOOP WITH AN OUTSIDE RESET TO LOWER THE SYSTEM
TEMPERATURE BASED ON THE OUTSIDE TEMPERATURE ON A STEAM SYSTEM JUST
ADD AN OUTSIDE RESET CONTROLER ON A BOILER SYSTEM WITH A 90PLUS
EFFICIENCY BOILER WITH OUTSIDE RESET CAPABILITY VARIABLE SPEED
PUMPING WITH A CONSTANT PRESSURE CONTROL SO WE DONT OVER
PRESSUREIZE THE CONTROL VALVES SET THE SYSTEM UP TO OPERATE WITH A
20 DEG DIFFERENTIAL TEMPERATURE
Slide 6
Example from Brandon
Slide 7
GRANDVALLEY STATE UNIVERSITY RENCE MEREDITH OBVIOUS REASONS
STUDENT LIVING CENTERS NEED A HEATING SYSTEM UPGRADE: WINDOWS OPEN
WHEN THE HEAT IS ON DIFFERENTIAL TEMPERATURE ON THE HEATING SYSTEM
IS LESS THAN 10 DEG F PUMP FAILURES, SEALS AND BEARINGS SELF OP
CONTROL VALVES FAILING AND MAKING NOISE SOLUTIONS FOR THE LIVING
CENTERS: REPLACE THE EXISTING NON CONDENSING 80 PERCENT BOILER
SYSTEM WITH A 90PLUS EFFICIENCY BOILER WITH OUTSIDE RESET
CAPABILITY ADD VARIABLE SPEED PUMPING WITH A CONSTANT PRESSURE
CONTROL SO WE DONT OVER PRESSUREIZE THE CONTROL VALVES SET THE
SYSTEM UP TO OPERATE WITH A 20 DEG DIFFERENTIAL TEMPERATURE ADD AN
EFFICIENT AIR REMOVAL SYSTEM ADD WATER FILTRATION AND CHEMICAL FEED
TO MAKE SURE THE NEW EQUIPMENT STAYS AT PEAK PERFORMANCE
Slide 8
Example from Rence
Slide 9
WAYNE STATE UNIVERSITY DAVE KUFFNER OBVIOUS REASONS EXISTING
SYSTEMS GROWING OLD WITH OLD TECHNOLOGY WINDOWS OPEN WHEN THE HEAT
IS ON DIFFERENTIAL TEMPERATURE ON THE HEATING SYSTEM IS LESS THAN
10 DEG F PUMP FAILURES, SEALS AND BEARINGS ZONE AND SELF OP CONTROL
VALVES FAILING AND MAKING NOISE BOOSTER SYSTEMS LEAKING AND RUNNING
24/7 SOLUTIONS FOR THE LIVING CENTERS: CONTROL THE HEATING LOOP
WITH AN OUTSIDE RESET TO LOWER THE SYSTEM TEMPERATURE BASED ON THE
OUTSIDE TEMPERATURE ON A STEAM SYSTEM JUST ADD AN OUTSIDE RESET
CONTROLER ON A BOILER SYSTEM WITH A 90PLUS EFFICIENCY BOILER WITH
OUTSIDE RESET CAPABILITY VARIABLE SPEED PUMPING WITH A CONSTANT
PRESSURE CONTROL SO WE DONT OVER PRESSUREIZE THE CONTROL VALVES SET
THE SYSTEM UP TO OPERATE WITH A 20 DEG DIFFERENTIAL TEMPERATURE
UPDATE BOOSTERS TO VFD AND NEW HIGH EFFICIENCY PUMPS
Slide 10
Wayne State University An Existing Pressure Booster System pump
was leaking on a system that Required several service calls every
month. It was time to review possible replacement of the pump as
seals would only Last months and 100s of thousands gallons of water
would go down the drain Before repairs could be completed each
time. With Tom Samson's help we reviewed the options of selecting
updated more Efficient pumps with Variable Speed operation. The
complete renovation cost about $37,000 with labor and piping. The
first months electric bills dropped in Excess of $35,000 and this
was great. But more, we have not had a complaint or Service call to
this sight in several years and The water / sewer savings / month
saves Several 10s of Thousands every year. You do the math what do
we save every Month On this one renovation. Easier to get more
renovation monies NOW>
Slide 11
10 What is ECM? Q: What does ECM stand for? A: Electronically
Commutated Motor Q: Is it a new technology? A: No. it was actually
created by GE in 1969 and ever since have been used in applications
from aerospace to automotive to HVAC!!! Q: What does that mean? A:
To commutate means to reverse every other half cycle of an
alternating current so to form a unidirectional current (per
dictionary) 11/13Engineering Presentation
Slide 12
11 What is ECM? Q: Why is a EC/DC motor more efficient? A: One
main reason, simply stated, is that the EC motor uses a permanent
magnet rotor and varies the polarity of the stator magnetic fields
where as a standard AC motor has to induce power into the rotor to
create opposing magnetic fields which can add up to a considerable
amount of loss. ECM rotor loss=0. Q: OK, but what about rotor slip?
Arent there still losses there? A: NO, an EC motor acts as a
synchronous motor, there is no slip loss which means primarily no
excess heat generation so considerably less dissipation is required
11/13Engineering presentation
Slide 13
12 What is ECM? Q: At full speed on an AC motor the typical
slip really doesnt generate that much heat because slip is minimal
and part of the design so how is the ECM that much better here? A:
This is true at full speed but what about at turndown? While the
design of the ECM is (at full speed) 30% to 50% more efficient than
the typical AC motor the real difference starts to come in during
variable speed conditions, as a typical AC motor begins to slow
down it becomes less and less efficient due to several reasons such
as excess slip compensation, increased heat from this compensation
generates considerable losses (typical turndown Max of an AC motor
is 50%). EC motors, being synchronous throughout the full speed
range allows the unit to maintain its efficiencies throughout the
full speed range and with no additional thermal load meaning
increased efficiencies of up to 80% overall compared to the
standard AC motors 4/13ECM Presentation
Slide 14
13 ECM with Permanent Magnet Rotor 11/13Engineering
Presentation Asynchronous to Synchronous Operation Eliminates motor
slip Responds to system demand No external sensors necessary 30% to
50% more efficient at full speed
Slide 15
14 What is ECM? Q: Why does the ECM not require external
sensors for the process control of the pump? A: In short, the brain
of the ECM is maintaining a synchronization between the spinning
magnetic fields of the stator and the rotor. As zones open and
close in the system, the impeller/rotor see more or less
resistance. The brain monitors the synchronization between the
opposing poles of the stator and the rotor and adjusts the stator
speed via PWM to match the rotor speed, eliminating slip.
11/13Engineering Presentation
Slide 16
15 AC with VFD vs. ECM with Square Wave Inverter
11/13Engineering presentation
Slide 17
16 Delta Pressure Variant Mode (DPv) Advanced Stratos Session16
Feet of Head Gallons Per Minute 40 0 0 100 20 50 25 12.5
Slide 18
17 Delta Pressure Constant Mode (DPc) Advanced Stratos
Session17 Feet of Head Gallons Per Minute 40 00 0 100 20 50 25
19 Delta Pressure Temperature Mode (DPt) Advanced Stratos
Session19 F Ft 43.3 35.3 3.3 19.3 27.3 11.3 32.0 204.3261.8 89.4
146.9 T min = 104 F P min = 12.1 Ft. T max = 167 F P max = 36.1
Ft.
Slide 21
20 Delta Pressure Temperature Mode (DPt) Advanced Stratos
Session20 F Ft 43.3 35.3 3.3 19.3 27.3 11.3 32.0 204.3261.8 89.4
146.9 T min = 104 F P min = 36.1 Ft. T max = 167 P max = 12.1
Ft.
Slide 22
212/2014Building Services Introduction DOWN THE DRAIN! D.O.E
AND U.S CENSUS BUREAU ESTIMATE BETWEEN 400 BILLION AND 1.3 TRILLION
GALLONS OF WATR ARE WASTED BY HOUSEHOLDS PER YEAR! D.O.E ESTMATES
THAT A MODESTLY SIZED RE-CIRC PUMP WILL USE 400 800 KWh/year (90
watts x 8760/ 1000) MANY STATES ARE LOOKING AT PASSING LAWS
REQUIRING DOMESTIC RECIRCULATION IN ALL NEW CONSTRUCTION PROJECTS
(DEMAND TYPE) TREMENDOUS ENERGY SAVING POTENTIAL WITH ECM LOW
HANGING FRUIT HP AND UP. EASILY THE MOST OVERSIZED CIRCULATORS IN
USE TODAY!
Slide 23
22 HOW MUCH DID YOU SAY?!?! Month/YearTitle Department/Author
(Insert > Header and Footer)
Slide 24
23 NO..REALLY! 150,000 GALLONS PER SECOND FLOW OVER THE
AMERICAN FALLS AND THE BRIDAL FALLS AT NIAGARA 600,000 GALLONS PER
SECOND FLOW OVER THE HORSESHOE FALLS ON THE CANADIAN SIDE OF
NAIGARA 750,000 GALLONS PER SECOND TOTAL 750,000 GPS X 60 SECONDS =
45 MILLION GALLONS PER MINUTE 45 MILLION GPM X 60 MINUTES = 2.7
TRILLION GALLONS PER HOUR AMERICAN HOMES WASTE IN ONE YEAR THE
EQUIVALENT OF WHAT GOES OVER NIAGARA FALLS IN A HALF HOUR!
Month/YearTitle Department/Author (Insert > Header and
Footer)
Slide 25
24 COST IN BTUS BTU = BRITISH THERMAL UNIT THOMAS TREDGOLD
INTRODUCED THE MEASUREMENT TO THE WORLD IN 1827 IT IS THE AMOUNT OF
ENERGY REQUIRED TO RAISE ONE POUND OF WATER ONE DEGREE FARENHEIT
FROM 62 DEGREES TO 63 DEGREES ONE GALLON OF WATER EQUALS 8.33
POUNDS 1.3 TRILLION GALLONS X 8.33 = 10,829,000,000,000 POUNDS
HEATING WATER FROM 100 DEGREES TO 120 DEGREES = 2O DEGREE DELTA TEE
10,829,000,000,000 POUNDS X 20 DEGREE RISE = 216,580,000,000,000
BTUS USED TO HEAT THE WASTE WATER (63,473,335,228 KW OR 63,473.335
GW) (( Palo Verde produces 3.3 GW annually)) ONE CUBIC FOOT OF
NATURAL GAS HAS 1,000 BTUS (THEORETICAL) AVERAGE COST PER CUBIC
FOOT = $0.016 216,580,000,000,000 X $0.016 = $3.5 TRILLION ANNUALY
Month/YearTitle Department/Author (Insert > Header and
Footer)
Slide 26
25 ECM Products: Stratos Z 4/13ECM Presentation Stratos Z (
Stainless Steel Volute ) NSF 61, Annex G certified (NSF 372)
Domestic recirculation Soft start high torque permanent magnet
rotor 6 sizes available Max head: 30 feet Max flow: 200 GPM 208/
230 volt single phase only Smart pump adjusts flow to system
changes (p-v, p-c and p-t) Non-volatile memory Flange sizes:1 , 1 ,
2 & 3 (High velocity) Interface modules for 0-10Vdc, LON,
BACnet and external control Dual pump mode (Duty/Stand by, Dual
pump) Infrared service/diagnostic tool available Pump performance
and system data logging Overload protection (voltage, dry run,
locked rotor, over temperature) Class A energy rating
Slide 27
26 Delta Pressure Temperature Mode (DPt) Advanced Stratos
Session26 F Ft 43.3 35.3 3.3 19.3 27.3 11.3 14 160210 60 110 T min
= 60 F P min = 36.1 Ft. T max = 110 P max = 12.1 Ft.
Slide 28
27Month/YearTitle Department/Author (Insert > Header and
Footer) This is a preliminary analysis of Wilo Z Domestic hot water
re- circulating pumps per our discussion last Tuesday. Following is
a comparison of a wilo z pump with a standard pump. Building 1506
Wilo Z: 1/8Hp, Single Phase, 208V Meter Installed Date: 2/10/2012
Meter Reading(03/29/2012):15KWh; $1.15 Pump Installed Cost: TFW
Electrical Rate:$.077/kwh Building 1511 Armstrong; Hp, Single
Phase, 110 V Meter Installed Date:2/13/2012 Meter
Reading(03/29/2012): 552KWh; $42.5 Pump Installed Cost: TFW
Electrical Rate:$.077/kwh Wilo Stratos Z vs. standard three piece
bronze domestic recirc pump
Slide 29
28 ECM Products: Stratos 4/13rECM Presentation Stratos (Cast
Iron Only) Soft start high torque permanent magnet rotor 208/230
volt single phase only Max head: 40 feet Max flow: 265 GPM Liquid
temperature range: 14 degrees F to 230 degrees F 8 sizes available
Three different control modes (p-v, p-c and p-t) Non-volatile
memory Flange sizes 1 , 1 , 2 & 3 (High velocity) Cataphoresis
coating Interface modules for 0-10Vdc, LON, BACnet and external
control Dual pump mode (Duty/Stand by, Dual pump) Infrared
service/diagnostic tool available Pump performance and system data
logging Overload protection (voltage, dry run, locked rotor, over
temperature) No external sensors Class A energy rating
Slide 30
29 ECM Products: Stratos D 4/13ECM Presentation Stratos D (Cast
Iron Only) Soft start high torque permanent magnet rotor 208/230
volt single phase only Max head: 40 feet Max flow: 480 GPM Liquid
temperature range: 14 degrees F to 230 degrees F 2 sizes available
Three different control modes (p-v, p-c and p-t) Non-volatile
memory Flange sizes: 2 and 3 Cataphoresis coating Interface modules
for 0-10Vdc, LON, BACnet and external control Dual pump mode
(Duty/Stand by, Dual pump) Infrared service/diagnostic tool
available Pump performance and system data logging Overload
protection (voltage, dry run, locked rotor, over temperature) Class
A energy rating
Slide 31
30 ECM Products: Giga 4/13 ECM Presentation 94% motor
efficiency (Beyond NEMA Premium efficiency) 10 sizes available 3 to
6 HP Max head: 165 feet Max flow: 275 GPM Fluid temperature range:
-4 to 284 degrees F Flange connection sizes: 1.5 to 2.5 460 volt, 3
phase only Control modes: DPv, DPc, P I D, constant speed Built-in
pressure differential sensors for use with DPc mode Interface
modules: LON, BACnet, MODbus Non-volatile memory Cataphoresis
coating Dual pump mode (Duty/Stand by, Dual pump) Infrared
service/diagnostic tool available More than 70% energy savings are
possible compared to uncontrolled pumps. Up to 33% energy savings
are possible over controlled inline split-coupled pumps
Slide 32
3111/13Engineering presentation Helix Excel High Efficiency
Multistage Pumps Available 2014 * Available 2015 NEW! Features
& Benefits >Highly efficient EC motor
>Efficiency-optimized, laser-welded 2D/3D hydraulics >Solid
stainless steel construction >Heads up to 130, flows up to 250
USGPM >Built-in electronic control module with Red Button
technology >Various control modes: speed control, constant
pressure, and PID >Uses cartridge-style mechanical seal for
quick and easy maintenance without removing the motor
>Additional roller bearing in pump housing protects against
axial thrusts >Optional interfaces for BUS communication using
plug-in IF-Modules >Electrical connection: 3~400 V/480 V (+/-10
%), 50/60 Hz, 3~380 V (+/-10 %), 60 Hz >Fluid temperature range:
-4F to 248F [-20 C to +120 C] >Max. Ambient temperature 104F
[40C] >Max. operating pressure 232/363 PSI >Protection class
IP 55 Applications >Water Supply and Pressure Boosting
>Process water >Washing Systems >Industrial Circulation
Systems >Cooling water >Irrigation
Slide 33
32Month/YearTitle Department/Author (Insert > Header and
Footer) Cleveland Clinic Main facility over 12 million Sq. Ft.
Aggressive energy reduction plan. Domestic re-circulation trial
realized 74% electrical reduction Wilo in master specification
Auditing and replacements ongoing
Slide 34
33Month/YearTitle Department/Author (Insert > Header and
Footer) Roswell Park Cancer Institute The campus spans 28 acres in
downtown Buffalo and consists of 15 buildings with about 2 million
square feet of space. 50 circulators audited HP range from HP to 40
HP Replacements sized to match H/Q 75% HP reduction at full load
Greater reduction possible with correct adjustment
Slide 35
34 An Example of Over Pumping at Immanuel Lutheran School
Original Circulators replaced with Stratos 3 x 3-40
Slide 36
35 An Example of Over Pumping Original Circulator 7.5 H.P, 3
Phase motor Original pump drew 6426 watts Circulator ran 24/7 from
October 1 st to April 30 th. 5040 hours x 6426 watts = 32,387,468
w/h per season. 32,387,468/1000 = 32,387 Kwh. 32,387 x $0.22/Kwh =
$7,125 per season for ONE circulator! Stratos 3 x 3-40 2 H.P, 230v,
1 Phase motor Circulator set to 25 feet of head. 360 watts. Pump
history indicated head setting could be lowered. Set point lowered
to 13 feet of head. Power consumption dropped to 250 watts. 250 x
5040 = 1,260,000 w/h 1,260,000/1000 = 1,260 Kwh. 1,260 x $0.22 =
$277.20 790 Kwh x $0.22 = $174.00 Flow vs. Efficiency 35
Slide 37
36 Vermont Housing Authority Powerpoint Title36
Slide 38
37Month/YearTitle Department/Author (Insert > Header and
Footer) 2 years of history Head set to 15 Max flow recorded 24 GPM
Target Flow 12 GPM Pump operated at 7.5 99% of the time Actual
Stratos needed for these apartment buildings, 1.25x3-20 90%
electrical savings
Slide 39
38Month/YearTitle Department/Author (Insert > Header and
Footer) Any Questions?