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M.E.R.I.T. (Macomb Energy Resource Integration Team) is a coordinated effort of Industry Professionals Team) is a coordinated effort of Industry Professionals and Manufacturers who take a Systems approach to deliver the best possible cost savings in energy, maintenance, labor and downtime for healthcare, education, power, retail and industry. This approach saves dollars and the environment. Merit then coordinates these efforts with the utility companies to achieve any rebates that are available to the end user.

What is MERIT

� The Macomb M.E.R.I.T. team takes a “Systems” approach to

review your - Water, Heating, Steam and Piping design to

help with the following;

� Reduce the energy consumption by improving efficiency of

the total system.the total system.

� Reduce maintenance cost by allowing the components to

work together.

� Reduce labor and downtime during replacement and repair

with innovative products.

� Reduce water consumption and sewage cost.

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Our approach has MERIT

• Our Experienced Team will perform a

complete energy audit of your facilities’

Water, Steam and Heating Systems.

• Utilizing In House and MERIT Partner product • Utilizing In House and MERIT Partner product

Experts to identify those “under performing

assets”

• Develop Customized Solutions that will reduce

consumption, save energy and document

payback.4

MERIT Partners and growing:

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MERIT Process Flow

Audit

• Water, Heating, Steam and Piping Design Systems

• Prioritize Assets Opportunities by quickest ROI

• Cost Saving/ROI Model

• Detailed Execution Plan- Milestone Planning

Implement

• Detailed Execution Plan- Milestone Planning

• Design – Construct - Train

Monitor

• Cost Savings Realized

• Utility Rebate Processing

• Payback Model

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Other MERIT Products & Services

• Rain Water Harvesting for Irrigation

• Waterless Technology for Restroom Facilities

• Documented Cost Savings

• Quarterly and Annual Performance Review • Quarterly and Annual Performance Review

• Utility Rebate Filing Assistance

• 100% Turn Key Services

• Materials Management and Logistics

• Alternative Technologies, Wind Turbine/Solar

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Next Steps

• Meet with your Maintenance and Engineering

leads

• Complete an Audit

• Delivery Customized Cost Saving • Delivery Customized Cost Saving

Recommendations

• Schedule Implementation Meeting

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Recent examples

• Pumps for Local Michigan College;

$143,000.00 Equipment cost

$ 66,385.00 Energy Savings per year

$ 34,810.00 Utility Rebates_________________$ 34,810.00 Utility Rebates_________________

Total payback for equipment 1.4 years

Examples Continued

• Boilers/water heaters for Local Michigan

College:

$310,000.00 Equipment cost

$116,600.00 Energy Savings per year$116,600.00 Energy Savings per year

$ 26,700.00 Utility Rebates_________________

Total payback for equipment 2.16 years

Cost of EfficiencyCost of Efficiency

On Site System ReviewOn Site System Review

•• Hydronic Boiler SystemsHydronic Boiler Systems– Review the existing system efficiencies

– Review actual heat load

– Select the highest efficiency best suited replacement boiler system

– Fuel cost comparisons– Fuel cost comparisons

•• Domestic Hot Water SystemsDomestic Hot Water Systems– Review the existing system

– Review actually sizing of existing equipment

– Select the highest efficiency best suited replacement water heater systems

– Fuel cost comparisons based on actual hot water used

Boiler Selection Boiler Selection -- ScenarioScenario

• Commercial Application

• Heat Load is roughly 1,500,000 Btu’s

• Existing Boiler – Estimated Efficiency at 75%

2,000,000 Btu Input / 1,600,000 Output (1.5 MBH)– 2,000,000 Btu Input / 1,600,000 Output (1.5 MBH)

• System Design Supply Temperature is 180º

• System Design Return Temperature is 160º

• Vented into Existing Masonry Chimney

• Cost for per Therm = $0.86

Boilers Lochinvar

Current

System

Thermal Efficiency 88% 75%

BTU's per Hour 1,700,000 2,000,000

Cost per Therm $0.86 $0.86

Hours per Day* 6 6

Days per year 195 195

Hours per year 1170 1170

Yearly Operation Cost $19,438 $26,832

Yearly Fuel Cost Savings $7,394

Installed Cost $25,572

Yearly Operating Cost

$10,000

$15,000

$20,000

$25,000

$30,000

Co

st

in U

S D

oll

ars

*Heating systems operate approximately 1760 hours per year,

consider climate where necessary.

Years to Payback 3.46 $0

$5,000

Lochinvar Current System

System Compaison

Boilers Copper Fin Copper-Fin II Power-Fin Intelli-Fin

Current

System

Thermal Efficiency 81% 85% 87% 97% 75%

BTU's per Hour 2,066,000 1,800,000 1,700,000 1,700,000 2,000,000

BTU'S per Hour - Output 1,673,460 1,530,000 1,479,000 1,649,000 1,500,000

Cost per Therm $0.86 $0.86 $0.86 $0.86 $0.86

Hours per Day* 6 6 6 6 6

Days per year 195 196 197 198 195

Hours per year 1170 1176 1182 1188 1170

Yearly Operation Cost $25,664 $21,417 $19,863 $17,906 $26,832

Yearly Fuel Cost Savings $1,168 $5,415 $6,969 $8,926

Installed Cost $11,000 $16,000 $24,000 $42,000

*Heating systems operate approximately 1760 hours per year,

consider climate where necessary.

Years to Payback 9.42 2.95 3.44 4.71

Bottom LineBottom Line

• There a numerous factors in selecting the highest efficiency boiler for a particular installation.

• All factors must be taken into consideration to get the most savings and performance out of your the most savings and performance out of your purchase.

• Choosing the wrong boiler for the wrong application can cost you more money than it did with the boiler that was replaced.

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Heat Recovery from

Continuous BlowdownCondensate

Steam

Blowdown valve

Flash

Hot well

Deaerator Head

Boiler

Feed pump

Flash vessel

Heat exchanger

Trap

Cold make-up

To drain

Boiler Blowdown Heat Recovery

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Steam Leaks Cost

• Comprehensive Steam Trap Surveys do

provide ample opportunity for energy savings

Orifice Diameter * LBS/Yr Loss **$10/1,000 Lbs **$12/1000lbs

1/16” 95,139 $ 951.39

$

1,141.00

$

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1/8” 380,139 $ 3,801.39

$

4,566.00

1/4" 1,522,229 $ 15,222.29

$

18,270.00

1/2" 6,088,918 $ 60,889.18

$

73,068.91

Cost Multiplier for

other steam pressure

15 psig- .26

200 psig- 1.87

50 psig- 1.43 600

psig- 5.35

150 psig - 1.43

600 psig - 5.35

* Continuous operations using Napiers formula: PPH=24.24 x Pabs x D^2

** Cost to Create 1,000 lbs of Steam

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High-Efficiency Urinal SystemsSloan High-Efficiency Urinal (HEU) systems, which are part of the Efficiency Series by Sloan®, combine the performance of both the fixture and the flush valve to ensure a true, water-efficient system. Urinals flush with as little as a pint of water and may be specified with a solar-powered Flushometer to save water and energy. Sensor-operated and manual flush valves deliver high performance, while minimizing maintenance.

Floor Mount ToiletsSloan High-Efficiency Toilets (HET), combined with a Flushometer ensure a true, water efficient system. High Efficiency Toilets flush 1.28 gpf (4.8 Lpf) of water and my be specified with a solar-powered Flushometer to save water and energy. Sensor-operated and manual flush valves deliver high performance, while minimizing maintenance.

Water Efficient FaucetsToday, Sloan faucets use as little as one half Waterfree Urinals

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Today, Sloan faucets use as little as one half gallon of water per minute – a conservative flow that saves water while aptly supporting proper hand washing hygiene. Sloan sensor operated faucets are either hardwired, battery, or solar powered.

Sloan Waterfree Urinals reduce water and sewer costs,maintenance and repair bills, and create morehygienic, odor-free restrooms. A Patented, SealedCartridge eliminates the need for water, typicallyconserving 40,000 gallons per unit per year. InstallingWaterfree Urinals along with other Sloan ConservationProducts ensures meaningful water savings. Inaddition, Sloan Waterfree Urinals do not require costlysupply piping to fixture.

Waterfree Urinals

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4.2 Million Gallons of

Water Saved Per Year

We utilize over 350,000 Square feet of office and manufacturing space at our facilities in Toccoa and Atlanta, Georgia.

• Flows to 10,000 GPM, heads to 400’

• Grease-lubricated bearings

• Bronze casing wear rings

End Suction Pumps

• Bronze casing wear rings

• Carbon vs. silicon carbide seal

• Channel steel base – No grouting required

• Bronze-fitted construction with bronze

• shaft sleeves

• Vertical Inlines, Horizontal Split Case

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• Consumption

• Production

Distribution

Train

• Distribution

• Variable Speed Pumping

• Variable Volume Pumping

• Cv’s / GPM of Coil or slightly greater 1#

• Coils etc / Importance of Flow Limiting

• Cv =gpm/delta P square root

Variable Speed Pumping in Hydronic SystemsVariable Speed Pumping in Hydronic SystemsVariable Speed Pumping in Hydronic SystemsVariable Speed Pumping in Hydronic Systems

Why use VFD’s?Why use VFD’s?Why use VFD’s?Why use VFD’s?

Global Studies Carried out by the European Commission

• Pumping systems account for 22% of the world’s electrical power demand

• Air Compressors 18%, Fans 16%, Cooling Compressors 7%, Other equipment 37%

• In some industrial plants pumps account for over 50% of the electrical load

• Rotodynamic (centrifugal) pumps account for 73% of all pumps• Rotodynamic (centrifugal) pumps account for 73% of all pumps

• Positive displacement (usually piston or screw types) account for 27%

• Over 95% of all pumps are oversized due to multiple butt covering!

• Up to 90% energy savings can be achieved using proper VFD techniques

• The pump can run closer to it’s Best Efficiency Point more frequently

The result of the effect of the Affinity Law is if we can operate a 125 Hp pump at half it’s speed and maintain the desired result of it’s overall

function it consumes only 5 Hp!

LCC = Cic + Cin + Ce + Co + Cm + Cs

• Cic – Purchasing cost (total can be less with VFD – ie: no bypass)

• Cin – Installation and commissioning cost (can be less with VFD)

Variable Speed Pumping

Why use VFD’s? Life Cycle Costs!

• Cin – Installation and commissioning cost (can be less with VFD)

• Ce – Lifetime energy cost (high savings with VFD)

• Co – Operation cost (labour the same)

• Cm – Maintenance cost (lower with VFD)

• Cs – Cost of lost production (lower with VFD – longer equipment life)

Properly applied VFD equipment can produce investment paybacks less than 2 years!

•ECM pump equal capacity to manufacturers of AC pumps you will see ECM technologies save 50% electrical use with comparable flows.•The Stratos style pump in addition to the Variable Speed controller, it utilizes DC ECM with internal control so that external building management is not required.•Each pump offers three methods of energy savings VFD, ECM and system control allowing 50–80% energy savings.•In addition to the pump energy savings proper flow to meet design •In addition to the pump energy savings proper flow to meet design delta T or temperature rise as designed by the boiler manufacturer; the owner can realize additional gas savings by operating at peak boiler efficiency.•A 98% efficient boiler operating at less than optional delta T is really operating at a very reduced efficiency as shown in their literature and the owners gas usage.

Adjustment of the Pumping Capacity

Changing the speed – manual multiple speed

H

n1

H1 n2 H1 n1

H2 n2

)(2

� =

Q1 n1

Q2 n2

� =

Pu

mp

ing

He

ad

H [

Ft]

H2

Q2 Volume Flow Q [USGPM]Q1

P1 n1

P2 n2

)(3

� ≈

H2 n2

)(

Adjustment of the Pumping Capacity

Changing the speed – the VFD way! P

um

pin

g H

ea

d H

[%

]

1,0 • n

0,9 • n

0,8 • n

0,7 • n

100

93

81

64

speed at 60 Hz

Pu

mp

ing

He

ad

H

Volume Flow Q [USGPM]

0,7 • n

0,6 • n

0,5 • n

0,4 • n

64

49

36

25

speed at 50 Hz

speed at approx. 40 Hz

Energy Rebate Template - Custom

Template A -- (Tertiary Coil/Unit Pumps)

Before RetrofitThe existing pump _Taco Model CC250C, 5.5, A4B2C1TL, _75_gpm @ _25_’tdh, Supply _var_F, Return _+4_F 4∆T1.0_hp _460_Voltage, _3_Phase, Actual _3.2_ Amp Draw, Average Hours Operation_8760__

After RetrofitNew WILO Stratos Model __2 x 3 – 35 __, _75gpm @ _13_’tdhSupply __var_F, Return _+9__F 9∆T_3/4_hp _230_Voltage, _1_Phase, Actual _0.5_ Amp Draw, Average Hours Operation_8760__

TWO-PHASEKILOWATT (kW) = VOLTS x AMPERES x POWER FACTOR x 2

10001000THREE-PHASE

KILOWATT (kW) = VOLTS x AMPERES x POWER FACTOR x 1.731000

New WILO Pump 0.21kW = 0.5 x 230 x .91 x 20.21 x 24 x 365 x 0.07 = $129.00/yearOld Taco Pump2.32kW = 3.2 x 460 x .91 x 1.732.32 x 24 x 365 x 0.07 = $1,423.00/year

Savings Per Year $1,294.00

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• Single point power connection

• Duplex Pumping• Automatic Standby• Automatic Alternation•• ECMECM Pumping Efficiency• Variable Speed Pumping• Expansion Tank• Small Foot Print• Air Dirt Separator• Hydraulic Separator• High Capacity Air Vent

SYSFMSYSFM--88PUMPING PACKAGEPUMPING PACKAGE

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• High Capacity Air Vent• Automatic Fill Valve• Chemical Feed Tank• System Thermometers• Simplified Installation• ASME Pressure Vessels• Energy Balance

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cut1.swf

The Amway Grand Has 2676 Tons of Cooling Operating At A Rate of 300 GPM On The

Side Stream With A Total Tower Water Flow Of 5672 GPM. The Filter Was Installed

The First Season Of The Season 2009:

Foul Thickness and

Resulting Increase in

Energy Use*:

Sacle Thickness (in)Foul Factor

(hrft2F/BTU)Energy Increase %

0.006 6.01 1,.000,000

0.012 5.15 1,.000,000

0.024 5.42 1,.000,000

0.036 4.24 1,.000,000

0.048 3.97 1,.000,000

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Increased Energy use means Decreased Efficiency and Higher Costs.

*Data From Carrier Corp.

SYSTEMS

OPERATION

SUMMARY

UTILITY

SEASONAL2008 Pre-Filtration

2009 Post-

Filtration

2010 Post-

FiltrationPercent Reduction Capital Recovery

June July August June July August June July August June July August June July August

Electrical (KWH) 1,676,400 1,563,600 1,646,400 4% $4,998.00

Water (GAL) 2,331,516 340,340 504,900 82% $26,586.00

Chemical

Treatment (GAL) 825 275 275 66% $14,000.00

2-YR Average $45,584.00

Evaporator FoulingFouling in the evaporator tubes will also increase energy costs. Fouled evaporator tubes can cause a drop in refrigerant evaporating pressure that reduces its density. As a result, the compressor must pump the gas to a higher pressure to remove an equivalent amount of heat from the chilled water. Again, the compressor must work harder, which increase energy requirements.

Fouling of 0.001 Increases Energy Consumption by 10%Based on $0.07 per kWH electricity cost and Power Factor of $ 0.91 on a Efficient Chiller at 40% load = $ 0.25 kW/TonBased on $0.07 per kWH electricity cost and Power Factor of $ 0.91 on a Efficient Chiller at 100% load = $ 0.57 kW/Ton

An Example of a 500 Ton Chiller operating at 100% for 2000 hours a season, which if you averaged a seasonal load this is fairly common and fouling often exceeds 0.0042.When making ICE for thermal storage units you can modify the hours and still reach the same costs.

Fouling of Reduction in Chiller Efficiency kW/Ton/100% load Wasted Energy/Ton/Season 500 Ton0.0008 9% 0.62 $100.00 $ 50,000.000.0017 18% 0.672 $204.00 $102,000.000.0025 27% 0.724 $308.00 $154,000.000.0033 36% 0.775 $410.00 $205,000.00

Side stream filtration down to 100 micron filtration can save real energy dollars on chiller efficiency.

______________________ Tower Basin & Condenser Tube Cleaning Cost

______________________ Cooling Water Chemical Treatment Cost / Filtering out Solids reduces Bioside Cost by 20%

______________________ Condenser Efficiency x Tonage x kW/Ton x 2000 hours/season (Clean vs. Fouled)

______________________ Make Up Water Savings keeping TSS counts down

One chiller manufacturer states without proper solids filtration efficiency is reduced by 10% in the first 24 hours of operation and continues down for the remainder of the season.

Filtering even a percentage of the total flow can yield significant return on investment (ROI).

A power generating company installed filtration to handle two percent of its 150,000 gpm flow. Its engineering staff determined that it would save $818,000 per year, including:

· $30,000 savings in tower basin and condenser tube

Screen Technology

cleaning costs;· $170,000 in cooling water chemical treatment costs;· $306,000 in improved condenser efficiency; and· $312,000 in high-efficiency fill costs.

“We figured our ROI would be under 18 months, and it turned out to be around 15 months,” he says. “That’s a good ROI. We ended up buying two more here

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ended up buying two more here and two bigger ones for the towers across the street.”

Screen Technology

1. Course Screen Filter Element2. Fine Screen Filter Element3. Inlet Connection4. Outlet Connection5. Rinse/Flush Valve6. Flushing Chamber7. Suction Scanner/HE Nozzle Assy8. Motor Drive

Screen Technology

Ford Sharonville – Potential Rain Water

Harvesting Example.

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RAIN WATER SUPPLY BASED ON HISTORICAL RAIN FALL DATA

B*C*D*E*F

MONTH

MONTHLY

AVERAGE

RAINFALL

CATCHMENT

FOOTPRINT

(SF)**

CONVERSION

FACTOR

RUNOFF

COEFFICIENTSAFETY FACTOR

MONTHLY

POTENTIAL

SUPPLY (GAL)

January 6.01 1,.000,000 0.623 0.9 1 3,369,807

February 5.15 1,.000,000 0.623 0.9 1 2,887,605

Florim USA – Potential Rain WaterHarvesting Example.

Clarksville, TN

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March 5.42 1,.000,000 0.623 0.9 1 3,038,994

April 4.24 1,.000,000 0.623 0.9 1 2,377,368

May 3.97 1,.000,000 0.623 0.9 1 2,225,979

June 3.77 1,.000,000 0.623 0.9 1 2,113,839

July 4.2 1,.000,000 0.623 0.9 1 2,354,940

August 3.44 1,.000,000 0.623 0.9 1 1,928,808

September 3.17 1,.000,000 0.623 0.9 1 1,777,419

October 2.63 1,.000,000 0.623 0.9 1 1,474,641

November 4 1,.000,000 0.623 0.9 1 2,242,800

December 4.67 1,.000,000 0.623 0.9 1 2,618,469

ANNUAL 50.67 28,410,669

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Consumers Energy Rebate

Incentives Program

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Incentives Program•Lighting

•Water Heating

•Heating and Cooling

•Motor and Drive

•New Construction

•Website:

http://www.consumersenergy.com/eeprograms/Business.aspx?id=4070&linkidentifier=id&itemid=4070

MERIT Partners:

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John Deere Green Tech: Steve FournierLochinvar: Mark SpearsMacomb Group Heating: Kevin O’NeilMichigan Steam: Kerry Hamilton & Paul TurnerSystecore: Jeff TurnerViega: Dan Holmes

WHY ???WHY ???WHY ???WHY ???

Chiller tubes are indeed a maintenance item to be cleaned every year, but as advertised by the chiller manufacturers they can lose 10% of their clean efficiency within the first 24hours operation due to particulate fouling. They continue to lose efficiency as the season wears on, would it be wise and energy conscious to prevent the fouling in the first place; maintaining design efficiency throughout the

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in the first place; maintaining design efficiency throughout the season? The reports by the chiller manufacturers show possible 30% loss in efficiency in the first months of operation with lowest efficiency operation during peak load season. By preventing the excessive fouling and operating at peak efficiency the energy consumption / load on the grid can be greatly reduced by numbers shown. This is directly related to electrical loading at peak demand timing. The other energy / labor / water savings just happen to be a by-product of mechanical efficiency.

Macomb Energy Resource

Integration Team

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Thank You