Energy Management in a Resource – Starved

Environment

Channing Starke

Director / Technical Services

Advanced Air Filtration

Resource Starved Environment

• Energy Usage Increasing

• Cost Increasing

• Labor Availability decreasing

• Budgets decreasing

From the Energy Information Administration Report - Annual Energy Outlook 2006

from 2004 to 2030 • Commercial Usage projected to be up 75%

• Residential Usage projected to be up 47%

• Industrial Usage projected to be up 24%

Series Title: Average Retail Price of Electricity, Commercial (Hundredth Cents per Kilowatthour, Including Taxes)

YearMonth 2001 2002 2003 2004 2005

1 7.36 7.49 7.65 7.69 82 7.57 7.71 7.64 7.83 8.23 7.71 7.73 7.71 7.92 8.14 7.75 7.66 7.9 7.88 8.275 7.79 7.81 8.02 7.98 8.456 8.13 8.1 8.39 8.46 8.947 8.4 8.3 8.47 8.6 9.048 8.37 8.25 8.39 8.66 9.159 8.29 8.09 8.07 8.53 9.21

10 8.3 8.08 8.04 8.23 8.8911 7.8 7.69 7.8 8.04 8.7412 7.71 7.66 7.68 7.81 8.23

Average 7.9 7.9 8.0 8.1 8.6

Primary Energy Use -Equipment Breakdow n

54%

5%

3%

12%

2%

14%

7%3%

Packaged A/C

Room A/C

Rotary Screw Chiller

Reciprocating Chiller

Absorption Chiller

Centrifugal Chiller

Heat Pump

PTAC

Energy Management

• Recover excess fan energy being used

• Recover excess compressor / chiller

energy being used

• Recover excess pump energy being used

Room coil (Before)

The same coil after Enzymatic Coil Cleaner

BioBio-- Fouling of CoilsFouling of Coils

A lower number indicates a greater resistance to heat transfer

0.60Biofilm

1.30Analcite Mineral Deposit

2.90Fe2O3 Iron Oxide

2.30CaSO4 Calcium Sulphate

2.60Ca3(PO4)2 Calcium Phosphate

2.60CaCO3 Calcium Carbonate

Thermal Conductivity (W/mK)Substance

Thermal conductivity comparison of deposit forming compounds and biofilm

ADVANCED AIR FILTRATIONHVAC System Solutions

Aluminium microstructure (scale 143.0 μm)

Polystyrene representing the Aluminium microstructure

Polystyrene (Representing Aluminium microstructure)

Polystyrene impregnated with a blue food dye to indicate the action of an Alkaline Cleaning process penetrating pathways

Typical Acidic Coil Cleaner

Acidic Coil Cleaner (HF, Hydrofluoric acid)

• Dilution Strength: 1 : 3*• Cycle: 1 minute

Very aggressive reaction is taking place !

* Concentration strength, as per product label, for foam cleaning of AC coils.

Acidic Coil Cleaner (HF, Hydrofluoric acid)

• Dilution strength: 1 : 3*• Immersion cycle: 4 Hours• Actual weight loss: 65.6672%• Weight loss (%): 65.67

* Concentration strength, as per product label, for foam cleaning of AC coils.

Exposed to the cleaner

Master

Alkaline Coil Cleaner (NaOH)

• Dilution Strength: 1: 4*

• Cycle: 1 minute

Alkaline Coil Cleaner (NaOH)

• Dilution strength: 1: 2*

• Cycle: 1 minute

* Concentration strength, as per product label.

Very aggressive reaction is taking place !

Very aggressive reaction is taking place !

Alkaline Coil Cleaner (NaOH)

• Dilution strength: 1: 4* with water

• Immersion cycle: 4 hours• Actual weight loss: 52.0531%• Weight loss (%): 52.05

Alkaline Coil Cleaner (NaOH)

• Dilution strength: 1: 2* with water

• Immersion cycle: 4 hours• Actual weight loss: 86.7604%• Weight loss (%): 86.76

Exposed to the cleaner

Mas

ter

Mas

ter

* Concentration strength, as per product label.

Alkaline Coil Cleaner (NaOH)

• Applied to the sample coil by spraying

• Dilution: 1: 4* with water• Cycle after application: 2 minutes

* Concentration strength, as per product label.

Very aggressive reaction is taking place !!!

Bioactive Enzyme Coil Cleaner • Non-acid, non-alkaline, non-toxic cleaning

process

• Cleaning process can be used on all coils

• Will not damage heat exchange coils

• Broad spectrum enzymes break down all biological material

• Completely biodegradable, washes down the drain safely

Enzyme Cleaner

• Dilution strength: 1: 20*

• Immersion cycle: 4 hours

• Actual weight loss: 0.0000%

• Weight loss (%): 0.00

Exposed to the cleaner

Mas

ter

Mas

ter

* Concentration strength, as per product label.

Energy Efficiency BTUs/ Hr

40.00

45.00

50.00

55.00

60.00

65.00

21.11 23.89 26.67 29.44 32.22 35.00

Outdoor Temp Celsius

BTUs x 1000

Before Cleaning Cleaned C/U Cleaned AHU Coil

ProceduresProcedures

• Filters removed

• Pretest Air flow, temperature drop and coil delta P recorded.

• Pre-test and Post-Test Air Flow readings recorded using TSI VelociCalc Plus 8385.

• Surfaces and coils Vacuumed.

• Coil Cleaner applied and allowed to penetrate coil for 15 minutes.

• Coil rinsed with water and allowed to dry.

• Coil Treated with Coil Treatment. Condensate Pan Tablet installed into drain pan.

• Run Unit for at least 60 minutes and record Post-Test temperature drop, coil Delta P and airflow readings.

• Filters installed and system buttoned up

Energy Impact Evaluation

• Based on previous field results, a test @ building 38 was conducted following the protocol established

• Actual air flow (Traverse) and temperature readings were entered into a spreadsheet derived from the ASHRAE fundamentals manual. This formula estimates total energy and makes assumptions difficult to quantify with multiple chiller installations. It has proven to be a reasonably accurate estimating guide.

• Given the results, additional buildings AHU’s were cleaned and treated.

IAQ Demonstration WorksheetAccount Name:

City: Pennsylvania

Contact:

Date: 6/18/2005 Unit Name: AHU 38 Fan on High

Size of Unit: 1 Notes: Cleaned & Treated

Initial Traverse Pre Cleaning Second Traverse Post Cleaning1780 1700 1730 1390 6600 2015 2070 2025 2115 8225

1230 1430 940 1040 4640 1495 1445 1600 1790 6330

1195 560 775 835 3365 1405 1560 1490 970 5425

180 58 91 33 362 1360 1170 1075 970 45750 0

14967 24555Average Velocity 935.44 Average velocity 1534.69

Number of Number of Test Points 16 CFM 5,846 Test Points 16 CFM 9,592

Duct Height (in) 30Dimensions Width (in) 30

Duct Area Sq. ft. 6.25 Second Test CFM 9,592 Initial Test CFM 5,846 in out diff

Coil Model. Serial # % Improvement 64.06%Coil Area Height (in) 48 before 71.8 64.8 7

Dimensions Width (in) 48 Approximate after 74.6 60.7 13.9

Coil Area Sq. ft. 16.0 Coil Tons 22.0 change 2.8 -4.1 6.9

Conversions 12MBTU/hr + 12,000BTU = 1 Ton of Airconditioning400 CFM of Coil Air Flow Capacity = 1 Ton of Airconditioning

Temp Drop

Energy Savings Worksheet ForBefore Cleaning After Cleaning Improvement

Air Flow (CFM) 5846 9592 64.1%

Temp Across Coil 7 13.9 6.9

BTU 44,199 143,992 99,793% BTU Improvement 225.8%Kwh 29.24Annual Kwh 30,789Total Annual $$ 1,693.38$ Unit nominal tonnage 22 76.97$ Air Flow/Ton (400) 266 436BTU Gain Per Ton 4536Kwh Per Ton 1399Savings Per Ton 76.97$

in out diff

before 71.8 64.8 7after 74.6 60.7 13.9

change 2.8 -4.1 6.9

Operation AssumptionsCost Per Kwh 0.055$ Days/Yr Usage 135Day Time Hours 10Night Time Hours 14Day Cycles/Hour 6Day Minutes/Cycle 5Night Cycles/Hour 6Night Minutes/Cycle 2

Temp Drop

260 days - no weekends313 - closed Sundays365 - open all of the time

SYSTEM EFFICIENCY ESTIMATE SHEET

Project Name: Date: 21-Oct-05Location: Building 38 Contact:

With modified Wet Bulb Engineer: Channing StarkeAHU Tagging: Contractor:

Coil Treatment Application Before After

CFM - Measured or Selected (VAV) 5,846 9,592

Entering Air Temperature - Dry Bulb °F 71.8 74.6Entering Air Temperature - Wet Bulb °F 66.0 66.0

Leaving Air Temperature - Dry Bulb °F 64.8 60.7Leaving Air Temperature - Wet Bulb °F 64.8 60.7

Total Cooling Capacity - Btuh 39,987 188,627 Sensible Heat -Btuh 44,196 143,995

Latent Heat - Btuh -4,209 44,632 Net Cooling Capacity Gain - Btuh 148,640

Pressure Drop "Across Coil" 0.93 " WG 0.73 " WGPressure Drop Reduction 0.2 " WG

Pressure Drop BHP Reduction 0.503 EER: 6.1Annual Operating Hours 3,240 Before

Energy Cost per kWh $0.055 EER: 10.9Annual Improvement (kWh cost) $4,462 After

Energy Savings Model for

258%Month 5$55,651

($27,624)

Summary of Cash Flow Month 1 Month 2 Month 3 Month 4 Month 5 Month 6(35,195)$

7,571$ 7,571$ 7,571$ 7,571$ 7,571$ 7,571$

($27,624) ($20,054) ($12,483) ($4,913) $2,658 $10,228

Month 7 Month 8 Month 9 Month 10 Month 11 Month 120 0

7,571$ 7,571$ 7,571$ 7,571$ 7,571$ 7,571$

$17,799 $25,369 $32,940 $40,510 $48,081 $55,651

1,250 Annual Contract Labor Cost 31,250$

492$ Cost of Coil Treatment 3,453$

35,195$

90,846$

Key Assumptions:

1. HVAC Contractor labor required per ton of AC = 25.00$

2. Energy savings based on 72.68$ per ton3 Cost of Electricity per KWH 0.070$

Investment Required (Cash Out)Savings (Cash In)

Net Cash Impact (Months 7-12)

ROIPaybackYear One Net Cash ImpactDeepest Red

Annual Utility Savings

Cost of Coil Clean

Total Annual Cost

Net Cash Impact (Months 1-6)

Tons of AC

ADVANCED AIR FILTRATION

Building Environment Solutions Tabulated Results for Demonstrations

Site Date Industry CFM CFM Delta Temp. Drop Delta Particle Count Energy

Before After % Before After T Change Saved/Ton

TTS AHU1 A-C, NJ Feb-05 Hospitality 634 719 13.5% 7.1 13.3 6.2 29.0% $68.46

TT S AHU2 A-C, NJ Feb-05 Hospitality 701 733 10.3% 13.2 15.5 2.3 50.4% $36.00

TT S AHU3 A-C, NJ Feb-05 Hospitality 757 1011 33.5% 7.1 13.7 6.6 21.3% $84.82

T R Rm768 A-C, NJ Apr-05 Hospitality 885 1050 18.6% 4.2 6 1.8 76.1% $58.12

T R Rm766 A-C, NJ Apr-05 Hospitality 1145 1429 24.8% 3.2 3.8 0.6 74.7% $39.81

B Rm 604 unit A A-C, NJ Apr-05 Hospitality 755 834 10.1% 9.8 12.2 2.4 85.2% $41.16

B Rm 604 unit B A-C, NJ Apr-05 Hospitality 736 858 16.5% 4.4 14.4 10 85.2% $136.40

B Rm 633 A-C, NJ Apr-05 Hospitality 211 274 29.9% 4.4 11.2 6.8 50.4% $32.13

A N G Pamona, NJ Mar-05 Office 3078 3432 11.5% 7 8 1 58.9% $126.98

S C H A-C NJ May-05 Hospitality 18265 21446 17.5% 13.3 18 4.7 NR $102.63

L Moorestown, NJ May-05 Office 4590 5542 20.7% 1 3 2 NR $106.64

S A-C NJ May-05 Hospitality 427 566 32.5% 7.8 14.3 6.5 NR $69.04

HJD Brookly, NY May-05 Healthcare 7546 9900 31.2% 9 12.5 3.5 NR $58.50

LCH Brooklyn, NY May-05 Healthcare 13222 19206 45.3% 9.5 10.5 1 NR $62.98

MC Phila. Pa Jun-05 Hospitality 9222 12318 33.6% 8.8 14.9 6.1 NR $155.70

TP Exter, Pa May-05Pharmaceutical6271 8988 43.3% 25.9 28.4 2.5 NR $166.81

AMH Linwood, NJ Jun-05 Education 11706 13377 14.3% 5.8 9.7 3.8 NR $85.51

THG Exter, Pa May-05 Residential 821 984 19.9% 14.2 16 1.8 NR $58.15

Hil. A-C NJ Jun-05 Hospitality 11707 13231 13.0% 6.8 14.2 7.4 NR $83.64

N.Y. EE #8 NY, NY Jun-05 Healthcare 10772 13291 23.4% 25.2 26.1 0.9 NR $137.80

N.Y. EE #7 NY, NY Jun-05 Healthcare 12308 16382 33.2% 15.9 16.6 0.7 NR $92.31

MI (base) NY, NY Jun-05 Healthcare 25048 29707 18.6% 20 23.4 3.4 NR $142.81

MI (AC-5) NY, NY Jun-05 Healthcare 12951 16550 27.8% 9.5 10.5 1 NR $40.68

SJH NY, NY May-05 Healthcare 23048 27921 21.4% 0.7 2.2 1.5 NR $41.25

Average All Tests 22.6% 3.4 59.0% $81.13

Comparison, Chilled water ΔT and ΔP pre and post cleaning and treatment.

AH-2001 25-Aug-05 1500 47 51 13,500 19.1 1.8AH-2002 25-Aug-05 0900 47 51 10,200 14.5 1.87AH-2003 25-Aug-05 1300 46 54 21,850 20 0.58AH-2004 25-Aug-05 1100 49 63 3,800 5.6 0.86

AH-2001 26-Aug-05 47 58 13,500 n/av 0.44AH-2002 26-Aug-05 16:25 46 67 10,000 n/av 0.85AH-2003 26-Aug-05 16:25 46 57 19,500 n/av 0.18AH-2004 26-Aug-05 47 63 3,800 n/av 0.54

BHp = [(cfm) * (Coil DP psi)] / [(229) * (Fan Eff.)] Fan Efficiency = 50%

Electricity = $0.052/Kw-hr

BHp savedAH-2001 5.4 168 $2,442AH-2002 3.8 66 $679AH-2003 1.7 66 $308AH-2004 1.0 66 $182

$3,611

After Cleaning

After Cleaning

74F 55%

Oper.Hrs./Week

Savings / Year

OAH (%)Delta P

CHW

Before Cleaning

72F 48%

Return Temp

CFM Flow

VFD OAT (ºF)AHU Date TimeSupply Temp

Change delta P

AH-2001 25-Aug-05 1500 47 51 13,500 19.1 1.8 1.039AH-2002 25-Aug-05 0900 47 51 10,200 14.5 1.87 1.515AH-2003 25-Aug-05 1300 46 54 21,850 20 0.58 0.449AH-2004 25-Aug-05 1100 49 63 3,800 5.6 0.86 0.493

AH-2001 26-Aug-05 47 58 13,500 n/av 0.761AH-2002 26-Aug-05 16:25 46 67 10,000 n/av 0.355AH-2003 26-Aug-05 16:25 46 57 19,500 n/av 0.131AH-2004 26-Aug-05 47 63 3,800 n/av 0.367

BHp = [(cfm) * (Coil DP psi)] / [(229) * (Fan Eff.)] Fan Efficiency = 50%Electricity / Kw-hr $0.07

BHp savedAH-2001 4.1 168 $2,583AH-2002 5.7 66 $1,397AH-2003 1.9 66 $479AH-2004 1.6 66 $388

$4,847Savings ? Ton based on 155 tons $31.27

After Cleaning

Oper.Hrs./Week

Savings / Year

AHUSupply Temp (°F)

Return Temp (°F)

After Cleaning

Before Cleaning

Delta P CHW Coil (in. w.c.)

Date TimeCFM Flow

VFD OAT (ºF)

48%

74F 55%

OAH (%)

72F

While customer generates it's own power @ $.055 / Kwh, energy saved would be from not purchasing power at a $.07 / Kwh rate

The constant in the BHp formula converts the coil delta P from " wc to psi and the CFM into volume / hour. The HP saved is the reduced power to move the required air through the measurably cleaner coil. The final saving formula multiplies the HP saved X hours / week X 52 weeks/ year x.746KW/ HP.

Change delta P

AH-2001 25-Aug-05 1500 47 51 13,500 19.1 1.8 1.039AH-2002 25-Aug-05 0900 47 51 10,200 14.5 1.87 1.515AH-2003 25-Aug-05 1300 46 54 21,850 20 0.58 0.449AH-2004 25-Aug-05 1100 49 63 3,800 5.6 0.86 0.493

AH-2001 26-Aug-05 47 58 13,500 n/av 0.761AH-2002 26-Aug-05 16:25 46 67 10,000 n/av 0.355AH-2003 26-Aug-05 16:25 46 57 19,500 n/av 0.131AH-2004 26-Aug-05 47 63 3,800 n/av 0.367

AH-2001 9-Nov-05 10:57 13,500 n/av 0.771AH-2002 9-Nov-05 11:05 10,000 n/av 0.355AH-2003 9-Nov-05 11:53 19,500 n/av 0.131AH-2004 9-Nov-05 11:30 3,800 n/av 0.367

BHp = [(cfm) * (Coil DP psi)] / [(229) * (Fan Eff.)] Fan Efficiency = 50%

Electricity / Kw-hr $0.07

BHp savedAH-2001 4.1 168 $2,583AH-2002 5.7 66 $1,397AH-2003 1.9 66 $479AH-2004 1.6 66 $388

$4,847

48%

74F 55%

OAH (%)

72F

Delta P CHW Coil (in. w.c.)

Date TimeCFM Flow

VFD OAT (ºF)AHUSupply Temp (°F)

Return Temp (°F)

After Cleaning

Before Cleaning

After Cleaning

Oper.Hrs./Week

Savings / Year

Follow up- After

Cleaning70

Why Part of This Program?

• Equipped – Detailed measurement of what’s going on.

• Part of the building solution. “Recomissioning”• No Conflict – don’t sell or install replacement

equipment• Concerned with the whole system

Why Energy

• As an Important immediate concern as IAQ• Yearly repeat program maintains gains, air

balancing independently confirms efficiency• Further strengthens customer relationship, most

maintenance is a cost, not R.O.I.• Ability to more easily be incorporated in this

years budget. Positive energy step that can be implemented now.

Contact Information

Channing Starke

Air-Vent Duct Cleaning / Advanced Air Filtration• 190 South main Street, Ambler Pa.• Phone- 215 641 0440• Cell- 973 592 2163• E- mail c.r.starke@worldnet.att.net