“Energy Conservation and the Electronically Communicated Fan”

• Theory • Benefits • Application • A Typical Installation

Presented by: Ed Hegwood, LEED AP O+M, Program Coordinator HVAC and Energy Efficiency Red Rocks Community College / Rocky Mountain Education Center

United States Patent 3,525,385 COMPUTER REFRIGERATION SYSTEM Ralph C. Liebert,

Cisco expects "global data center traffic will grow threefold and reach a total of 7.7 zettabytes annually by 2017.“

By Steven J. Vaughan-Nichols for Networking | October 15, 2013

• zettabyte is a billion terabytes

7.7 zettabytes is equivalent to:

107 trillion hours of streaming music--about 1.5 years of continuous music streaming for the world’s population in 2017.

7.7 zettabytes is equivalent to: 19 trillion hours of business Web conferencing--approximately 14 hours of daily web conferencing for the world’s workforce in 2017.

8 trillion hours of online high-definition (HD) video streaming--about 2.5 hours of daily streamed HD video for everyone in the world in 2017.

Why are the Following Utilities

doing Prescriptive Rebates

for

Electronically Communicated

Motor Driven Fans

Electrically Commutated Motors (ECM) $350/kW

The Peak Demand Rebate program is a custom rebate program for medium to large business customers with the goal of obtaining on-peak summer electric demand reduction. It is designed to provide flexibility in terms of eligible measures (including lighting and HVAC). Rebates only apply to retrofits. Program participants provide verified electric demand savings through the installation of eligible DSM measures (energy efficiency and/or load shifting) in return for a $400 per kW incentive. Eligible projects must combine to a minimum 20 kW demand reduction during the summer peak period - defined as 3 to 6 p.m., Monday through Friday, from June 15 through September 15, excluding federal holidays. https://www.csu.org/CSUDocuments/busrebatesoverview.pdf

Custom Efficiency Colorado businesses earn rebates on energy-saving custom equipment With our Custom Efficiency rebates, you can: Earn rebates to offset the cost of energy-saving equipment and processes

Up to $400/kW of electricity saved and/or Up to $7/Dth saved for natural gas projects

Apply a wide variety of equipment and processes that are not covered under other rebates Lower your operating costs with energy-saving measures Note: Rebate amounts vary according to the project’s energy savings. http://www.xcelenergy.com/Save_Money_&_Energy/Find_a_Rebate/Custom_Efficiency_-_CO

All of these fans have the potential to be retrofitted to EC

Fans

Theory

How It Works

The EC fan has a DC (direct current) motor operating off of an AC (alternating current source). The EC (electronically commutated) brushless motor has permanent magnets in the rotor, which revolves around the outside of the motor.

How It Works

The EC motor behaves like a brushed DC motor as the speed under load is proportional to the drive voltage and the developed torque is in linear proportion to the current. The EC motor has a sensing and feedback circuit to ensure that the correct speed is obtained.

Benefits

Today Air is the Low Cost Way to Move Heat

• Dell warranties its servers for fresh-air cooling

solutions are capable of running at 104˚ degrees Fahrenheit for up to 900 hours per year and 113˚ hours Fahrenheit for 90 hours per year.

Airflow Efficiency

This metric characterizes overall airflow efficiency in terms of the total fan power required per unit of airflow. Total Fan Power (W) / Total Fan Airflow Cubic Feet per Minute (CFM) 1.25W/CFM (Standard) Exiting CRAC/CRAH

Units

0.75 W/cfm (Good)

0.5 W/cfm (Better) with EC Fans

Retrofit for Efficiency Improvements for Legacy Data Centers and other Commercial Buildings

What’s in it for You?

kW Reduction

Application

Forward-curved blades use blades that curve in the direction of the fan wheel's rotation. Efficiency is less than backward curved bladed impellers.

The backward curvature mimics that of an airfoil cross section and provides good operating efficiency with relatively economical construction techniques. Backward-curved fans are much more energy efficient than forward curved fans.

Replacing the existing forward curved fans with EC (electronically commutated), brushless motors and backward curved fans. Traditional fans are belt-driven which can absorb 5 to 15 per cent energy even when they are correctly installed, plus the cost of replacement and regular servicing. No belts also means no belt dust.

Value added maintenance savings are the removal of belts, fan shaft and bearings.

A further advantage of using these alternative fans, is the vastly improved airflow across the cooling coil. Most CRAC/AH unit existing fans are positioned just under the cooling coil, which causes three unnecessary issues: 1. FC fans block part of the coil, reducing the surface area and its efficiency. 2. The airflow has to split on either side of the FC fan, and then turn 90° before it can be

distributed.

3. Air for FC fans is distributed into the floor slab, causing turbulence and resistance, which uses up energy, EC fans can be located much lower down in the floor, thus removing the dead spots over the coil’s surface and reducing turbulence and resistance.

Forward Curved Fan EC Fan

17”

Reduced AIR

FLOW AREAS

Recirculation Zones

Level 3 DC -23 ea. Data Aire DA CRAC ←Customer Yellow = Inputs

Enter your total electricity cost ($/kWh)→ $0.075 Total Amps ↓ CFM For EC Fans→ 67 402,000

Enter the number of EC Fans needed (6,000 CFM Each @ .05")→ 67 50.61 Fan Utilization Factor 71.94% Voltage Voltage

Enter Cost per EC Fan to Retrofit Unit→ $2,732 Rated Fan Amps→ 19.6 Rated 480

Enter Motor Voltage→ 480 EC Fan CFM De-Rated Fan Amps 19.60 Actual→ 480

Enter % of Flow→ 60% 241,200 Actual Amps→ 14.1 Derate = 0.00%

Enter Number of CRAC/CRAH Units to be Retrofitted→ 23 Total Amps ↓ Corrected CFM 326,149

Existing Unit Total Fan Motor Current Amp Draw/ phase 14.1 324.30 CFM Correction→ 1.212

Enter Existing Unit Total Fan Motor POWER FACTOR → 0.85 CFM

Enter Existing Unit Total OEM Rated CFM → 11,700 Job Site CFM Alt Ft Correction

Existing Unit Fan Motor Utilization FACTOR 71.94% 234,628 4000 1.157

YOUR ESTIMATED ENERGY SAVINGS & PAYBACK kWh kW 4200 1.166

Annual Energy Spend Belt Drive FC Fan $150,390 2,005,198 228.90 4400 1.175

Annual Energy Spend EC FAN $27,359 364,788 41.64 4600 1.184

TOTAL ANNUAL SAVINGS $123,031 1,640,410 187.26 4800 1.193

TOTAL EC FAN UPGRADE COST $183,044.00 + TAXES 5000 1.202

EC FAN Maintenance COST Avoidance $4,600.00 $200/Unit 5200 1.212

ROI/ PAYBACK in Years 1.45 kW Saved 5400 1.222

Rebates @ $???./kW $74,905 187.26 5600 1.232

ROI/ PAYBACK with Rebates in Years 0.84 $400 < Rebates 5800 1.2426000 1.252

Fan Motor Heat Gain Reduction ( Increased Cooling to Floor) 622,167 BTUs-Cooling 6200 1.26

Total Capacity Made Available and returned to your Environment 273.69 Amps/phase Existing Retrofit 6400 1.268

Water Savings at Power Plant 623,356 Gallons / Year Fan W/kBTUs Fan W/kBTUs 6600 1.276

Carbon Dioxide Equivalent Avoided 2,460,615 Pounds / Year 69.86 12.71 6800 1.284

7000 1.292

W/CFM W/CFM

1.18 0.22

EC Fan Energy $ avings Calculator ©EE

Assumptions: 8760 Hour/Year Operation, 72 oF 35% RH. Energy Savings based on average EC fan modulation and

amp draw as identified

Disclaimer: Calculations are based on estimates and the assumptions shown above. While every precaution has been taken to ensure

accuracy and completeness, We assume no responsibility and disclaim all liability for damages resulting from use of this information or for

any errors or omissions.

$0

$20,000

$40,000

$60,000

$80,000

$100,000

$120,000

$140,000

$160,000

Annual Energy SpendBelt Drive FC Fan

Annual Energy SpendEC FAN

ENERGY COST COMPARISON

ABC Data Center

EC FAN Savings Points - EMERSON

• Energy Efficient EC fan savings up to 36% Variable Fan Speed Direct Air Path Lower Energy Consumption

• 16300 CFM

• 8.6kW

Blower System “A” Blower System “B” Blower System “C”

• 16400 CFM

• 6.9kW

• 16400

CFM • 5.5kW

jjjjjjjjjjjj

Efficiency The efficiency of the EC motor (typically > 90%) is higher than that of traditional asynchronous

AC motors (typically < 80%) and generates less heat, as there are no slip losses, less copper and

iron losses. The EC motor is also more efficient than alternative speed control methods including:

Inverter, AC frequency control, Triac voltage control, Multi-taped transformer voltage control (steps),

and Star/Delta switch (two step)0

The DC motor is inherently more efficient than AC motors and,

therefore, operates at a lower temperature putting less thermal

stress on windings and bearings, while also reducing the

amount of heat introduced into the air stream (lessening the

impact on “total” vs. “net” capacity of the CRAC unit).

+17,681

A Typical Installation

EC fan Install completed in “live”

DATA CENTER

67 FORWARD CURVED FANS AND MOTORS TO BE REPLACED

WITH EC MOTORS AND BACKWARD-CURVED FANS

Staging Area

Tech removing old motors and wiring

Tech removing old motors and wiring

Note: drop cloth on floor and organized tools

Old fans were palletized for easy

moving out of center

New EC fans ready for install

Three EC fans in place 30 Ton Unit

20 Ton unit , two fans installed 67 Fan Project Completed in Three Weeks

Pre-Project Measurements

6.30

8.15

5.94

7.98 8.27

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

CRAC Measured KW 10 day average at a constant air volume

Avg. KW

CRAC Unit Number 1 4 8 13 20

Post-Project Measurements

1.77 1.85 1.80 1.73 1.86

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

CRAC Measured KW10 day average at a constant air volume Avg. KW

CRAC Unit Number 1 4 8 13 20

KW Measurement Comparison

6.30

8.15

5.94

7.98 8.27

1.77 1.85 1.8 1.73 1.86 1.10

2.10

3.10

4.10

5.10

6.10

7.10

8.10

9.10

KW

Measu

rem

en

t

CRAC KW Measurement Comparison

Pre

Post

1 4 8 13 20

Actual KW Differences

Unit# 1 4 8 13 20

PRE 6.30 8.15 5.94 7.98 8.27

POST 1.77 1.85 1.80 1.73 1.86

Reduction-kW 4.53 6.30 4.14 6.25 6.41

This was a sampling of the overall project,

a total 67 Motors and fans were replaced.

110 kW total with more kW if fans are tied to server though put ***.

Fan Law (Cube Law): The motor power varies with the cube of the

motor speed. ***

Reduced Motor kW = Existing Motor kW x (speed2/speed1)3

10% Reduction

20% Reduction

Previous generations of servers may have used 400 watts but still consumed 60% to 70% of that power even without performing any useful work, according to John Stanley, senior analyst for data center technologies at the 451 Group. “We’ve improved energy efficiency a lot, and newer generations of 1U commodity servers are improving,” he said. “Now an idle server might only use 25% to 50% of [its] total power.” Next-generation servers will use only a fraction of their total power when idle and actively power off when unneeded.

Advantages of the EC Fan Imbedded Sensors in the Servers • The ultimate goal of this project and a

similar one conducted last year by Lawrence Berkeley National Labs*** is to link IT equipment directly to power and cooling systems, so that supply can be adjusted automatically to match demand.

***The project has been a success, The main

goal we had was to show that you could do this, that you could use the sensors in the IT equipment to control the building systems, and we achieved that," - Bill Tschudi, a program manager at Lawrence Berkeley. • The amount of energy saved will vary

depending on how efficient a data center is to begin with, he said. He predicted that most data centers would see a return on their investment within a year.

Bigger Air Handling Units

A rule of thumb is that for each degree you can reduce your condenser temperature, you will save about 1.5% on your cooling energy costs.

This diffuser is designed to recover this wasted energy by purposely and efficiently decelerating the flow and reducing swirl, boosting the pressure rise of

the impeller.

Aerodynamic efficiency and airflow is increased and acoustic noise is reduced.

Applications such as rooftop refrigeration condensers and heat exchangers can benefit from a dramatic noise reduction without sacrificing performance

Questions or Comments?

Thank you for Attending

Ed Hegwood

Office 303-914-6202

Cell-303-656-0374

ed.hegwood@rrcc.edu

www.rmecosha.com/HVAC

Water Efficiency in Commercial

Buildings

October 22,2013

24 x 7 EXCHANGE

Why does Denver Water care?

Reduce water & energy (heating) costs for our customers

Reduce operating costs (water treatment, pumping, chemicals)

Reduce wastewater discharge & costs Save potable water for expanding population ◦ Recycled and New Supply

Drought response

Developing a Water Budget

Indoor Uses ◦ Number of Residents, Employees, Fixtures

Outdoor Uses ◦ Irrigated Area, Vehicle Washing

Industrial Processes ◦ Cooling Equipment, RO systems, Cleaning

Water Budget

Indoor Water Uses Fixtures must meet standards set by Energy Policy Act of 1992

Fixture

EPAct of 1992 Standards for Plumbing Fixture

Water Use

Water Closets (gpf) 1.6

Urinals (gpf) 1.0

Shower Heads (gpm)* 2.5

Faucets (gpm)** 2.2

Faucet Replacement Aerators** 2.2

Metering Faucets (gal/cycle) 0.25

* When measured at a flowing water pressure of 80 pounds per square inch (psi).

** When measured at a flowing water pressure of 60 pounds per square inch (psi).

On the market since late 1980s

After initial opposition

◦ IPC accepted waterless urinals in 2006

◦ UPC accepted waterless urinals in 2009 – BUT water still has to be piped to the urinal & capped off

Issues: smell, clogged drain lines, maintenance staff training

New Waterless Urinal test at Denver Water

Waterless Urinals: The Debate

Viable alternative to domestic water

Not always available in all areas

Water quality does not meet federal drinking water standards

Recycled Water

Commercial Indoor Rebates Multi-Family/Commercial Multi-Tenant Sub-Metering $40

High Efficiency Urinal $100

Commercial Warewashing Equipment $300

Cooling Tower Conductivity Controller $500

Cooling Tower Make-Up or Bleed Meters $50

Coin/Card-Operated Laundry Equipment $150

High Efficiency Toilets $75

Flushometer Bowl/Valve Combination (1.28 gpf) $125

Commercial Outdoor Rebates

Weather-based Smart Controllers ◦ 25% of purchase price up to $2,500

Rotary Nozzles ◦ $2 per nozzle ($20 min and preapproval for >$2,500)

Evaluating Irrigation Efficiency Contracts

Commercial Incentive Program

Commercial, Industrial and Institutional customers can earn 50% of project costs up to $40,000 for improving the efficiency of their processes.

Earn $18.50 for every 1000 gallons of water saved over a one-year period.

Must meet a minimum savings requirement of 100,000 gallons per year to qualify.

Holds customer accountable

Paying for results

Versatile

Allows for long-term savings component

Performance Based Contracts

Past Projects

Hospital sterilizers

RO for vehicle washing

Replace water-cooled compressor

Re-circulating water to cool commercial washing machines

Add Ozone treatment to laundry facilities

Cooling Processes

Eliminate single-pass cooling ◦ Often associated with equipment cooling for pumps, compressors, ice machines, air conditioners, etc.

Replace water-cooled with air-cooled models

Identify opportunities to capture process water for reuse later

Using Reuse

• In-plant “used” water

• Softener rinse

• RO reject

• Boiler blowdown

• Condensate

• Gray water

• Even cooling tower blowdown with pre-treatment

Cooling Tower

Incentive Program

Presented by

Rick Alvarado

Conservation Tech II

Cooling Tower Incentive Program Director

Denver Water

Cooling Tower Incentive Program

• Commercial, Industrial and Institutional customers can earn 50% of project costs up to $40,000 for improving the efficiency of their processes.

• Earn $18.50 for every 1000 gallons of water saved over a one-year period.

• Must meet a minimum savings requirement of 100,000 gallons per year to qualify.

Incentive Program Requirements

• Make-up and blowdown meters

• Controller capable of monitoring tower conductivity

• Communications package allowing for monthly reports to Denver Water

Water Conservation

• Increase cycles of concentration • Quickest method of water conservation

• No downtime

• Consult a chemical supplier

Cycles

5

8

Savings

Makeup water

15 gpm

10,800 gpd

3,942,000 gpy

13.75 gpm

9,874 gpd

3,604,000 gpy

1.25 gpm

926 gpd

338,000 gpy

$1,000/year @ $2.96/1000 gal

Example—800 Ton HVAC Tower

Blowdown water 3 gpm 2,160 gpd 788,400 gpy 1.75 gpm 1,234 gpd 450,514 gpy 1.25 gpm 926 gpd 338,000gpy $659/year @ $1.95/1000 gal

Assume: average 25% heat load, 24 hour/day, 365

Total Savings: $1,659/year + chemical costs +

$7,260 incentive

Water Treatment Programs

• Traditional chemical treatment

• Green chemical treatment

• Physical water treatment

Traditional chemicals

• Corrosion inhibitors (polysilicates, phosphonates, azoles, etc.)

• Scale inhibitors (phosphonates, polymers)

• Fouling control (filtration, dispersant & fluidizer polymer chemicals)

• Microbio control (chlorine, bromine, ozone, H2O2)

Green Chemical Treatment

• High-bonding crystal modifiers

• Originally developed for lead poisoning

• Typically biodegradable & biorenewable

• Reduce blowdown by 90%

• Zero-blowdown possible

Cycles

5

40

Savings

Makeup water

15 gpm

10,800 gpd

3,942,000 gpy

12.3 gpm

8,860 gpd

3,234,500 gpy

2.7 gpm

1,940 gpd

707,500 gpy

$2,094/year @ $2.96/1000 gal

Example—800 Ton HVAC Tower

Blowdown water 3 gpm 2,160 gpd 788,400 gpy 0.3 gpm 220 gpd 80,900 gpy 2.7 gpm 1,940 gpd 707,500gpy $1,380/year @ $1.95/1000 gal

Assume: average 25% heat load, 24 hour/day, 365

Total Savings: $3,474/year + chemical costs +

$15,198 incentive

Physical Water Treatment

• A non-chemical method of water treatment for the purpose of scale prevention or mitigation

• Typically electromagnetic solenoid coils

Physical Water Treatment

• Pulsed low (60 Hz) &

high (10-100 kHz)

frequency EM fields

Source: Clearwater Systems

• Electrolysis produces a high potential for scaling

• Eliminates chemical handling

• Cathodic reaction:

Non-Chemical Water Treatment

OHCOCaCOOHCOCa

OHHeOH

223

2

3

2

2

_

2

2

222

Cooling Water System Audit (2009)

• 113 towers – average 4 cycles

• Uncontrolled water leaks

• Overflow of basins

• High tower drift

• No metering

• Little testing

• Inoperative controllers

Denver Water’s

Recycled Water Quality

• Conductivity 360-1250 micromhos

• Calcium Hardness 40-70 CaCO3

Action Plan for Facility Engineers

• Get information about your system

• Look for leaks

• Determine cycles of concentration

• Find out how much water is being used

• Meter your system!

• Insist on higher cycles

• Documentation

• Wastewater Credits

Cooling Tower Incentive Program

Getting Started • Choose a project that will improve water-use

efficiency or make use of reuse.

• Contact Denver Water for a pre-installation visit and inspection.

• Denver Water will issue a contract detailing the terms of the project.

• A Conservation staff member will conduct a post-installation inspection to verify operation.

• Denver Water will track your water use and issue quarterly reports.

• After a year of monitoring, Denver Water will issue a check for the amount of water saved.

• Contract between Denver Water and customer

(non-SFR), in which Denver Water pays the

customer for actual water savings achieved as a

result of the customer making water

efficiency/conservation changes to their tower.

What do we mean by

performance-based contract?

Free Audits: Indoor

• Determine water use

• Check meters

• Check for leaks

• Install low-flow features

• Identify maintenance issues

• Identify conservation opportunities!

43

Largest indoor water use

25% of total

Free Audits: Outdoor

44

• Visual inspection

of each zone

• Discover leaks,

breaks,

maintenance

issues

• Scheduling

Recommendations

• Identify efficiency

opportunities

Adjusting your irrigation schedule

monthly can save 30% of the water

used to irrigate every year.

The Importance of Maintenance

Contact

Rick Alvarado

Conservation Tech III

Office 303-628-6470

Cell- 303-994-6787

gregory.alvarado@denverwater.org

Denver Water

1600 West 12th Avenue

Denver, Colorado 80204

www.denverwater.org

www.denverwater.org