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.
1
Title – Department/Author (Insert > Header and Footer)
Month/Year
When a component fails its time for the engineer in all of us to kick in.
We’ve found that the place to start is looking at the overall design.
Let’s say it’s 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 you’re 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.
2
Title – Department/Author (Insert > Header and Footer)
Month/Year
The How and Why
ALMA COLLEGE
BRANDON SMITH
GRANDVALLEY STATE UNIVERSITY
RENCE MEREDITH
WAYNE STATE UNIVERSITY
DAVE KUFFNER
• Is this system Maintenance?
• Or is this Energy Savings?
3
Systecore Inc
•
•
•
•
Simply applying proper components
50% reduction in energy cost
No monies from Energy Budget
Simple maintenance cost
06/14/2015
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
DON’T OVER PRESSUREIZE THE CONTROL VALVES
SET THE SYSTEM UP TO OPERATE WITH A 20 DEG DIFFERENTIAL TEMPERATURE
GVSU Example
•
•
Why?
•
Failed Boiler Heat exchangers, Pumps, Seals and Bearing
failures
•
System Noise
•
Windows Open/Frozen Fintubes
•
Oversized systems
How?
•
•
6
AUX Projects Funding – 4 year phased plan
What?
•
Complete Mechanical Room Retrofit
•
Boilers, Pumps, Air/Dirt Seperator, Filtration and Chemical
system, Controls
GVSU Example
•
•
7
Costs
•
Year 1 - $225k
Year 2 - $527k
•
Year 3 - $245k
Year 4 - $275k
Benefits
•
Systems work as designed
•
Boiler and Pumps provide heat based on demand rather than
constant speed
•
Initial Energy Savings – 33% (based on heating degree days)
•
System Repair and Service Call Savings
•
Simple Controls Sequence
• 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
DON’T 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
•
•
•
•
•
• 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 100’s 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 10’s 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>
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)
12
Engineering Presentation
11/13
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? Aren’t 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
13
Engineering presentation
11/13
What is ECM?
• Q: At full speed on an AC motor the typical slip really doesn’t 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
14
ECM Presentation
4/13
ECM with Permanent Magnet Rotor
15
•
Asynchronous to Synchronous
Operation
•
Eliminates motor slip
•
Responds to system demand
•
No external sensors necessary
•
30% to 50% more efficient at
full speed
Engineering Presentation
11/13
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.
16
Engineering Presentation
11/13
AC with VFD vs. ECM with Square Wave Inverter
17
Engineering presentation
11/13
Delta Pressure Variant Mode (DPv)
40’
25’
Feet of Head
20’
12.5’
0’
0
50
100
Gallons Per Minute
18
18
Advanced Stratos Session
Delta Pressure Constant Mode (DPc)
40’
25’
Feet of Head
20’
0’
0
50
100
Gallons Per Minute
19
19
Advanced Stratos Session
Stratos Performance Charts
20
20
Advanced Stratos session
Delta Pressure Temperature Mode (DPt)
T min = 104° F
43.3
P min = 12.1 Ft.
T max = 167° F
35.3
Ft
P max = 36.1 Ft.
27.3
19.3
11.3
3.3
32.0
89.4
146.9
204.3
261.8
°F
21
21
Advanced Stratos Session
Delta Pressure Temperature Mode (DPt)
T min = 104° F
43.3
P min = 36.1 Ft.
T max = 167°
35.3
Ft
P max = 12.1 Ft.
27.3
19.3
11.3
3.3
32.0
89.4
146.9
204.3
261.8
°F
22
22
Advanced Stratos Session
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 ¼ HP AND UP.
• EASILY THE MOST OVERSIZED CIRCULATORS IN USE TODAY!
23
Building Services Introduction
2/2014
HOW MUCH DID YOU SAY?!?!
24
Title – Department/Author (Insert > Header and Footer)
Month/Year
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!
25
Title – Department/Author (Insert > Header and Footer)
Month/Year
COST IN BTU’S
•
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 BTU’S 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 BTU’S (THEORETICAL)
•
AVERAGE COST PER CUBIC FOOT = $0.016
•
216,580,000,000,000 X $0.016 = $3.5 TRILLION ANNUALY
26
Title – Department/Author (Insert > Header and Footer)
Month/Year
ECM Products: Stratos Z
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 ¼”, 1 ½”, 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
27
ECM Presentation
4/13
Delta Pressure Temperature Mode (DPt)
T min = 60° F
43.3
P min = 36.1 Ft.
T max = 110°
35.3
Ft
P max = 12.1 Ft.
27.3
19.3
11.3
3.3
14
60
110
160
210
°F
28
28
Advanced Stratos Session
Wilo Stratos Z vs. standard three piece bronze domestic recirc pump
This is a preliminary analysis of Wilo Z Domestic hot water recirculating 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; ½ 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
29
Title – Department/Author (Insert > Header and Footer)
Month/Year
ECM Products: Stratos
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 ¼”, 1 ½”, 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
30
ECM Presentation
4/13r
ECM Products: Stratos D
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
31
ECM Presentation
4/13
ECM Products: Giga
• 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
32
ECM Presentation
4/13
Available 2014
Helix Excel
High Efficiency Multistage Pumps
Features & Benefits
33
>
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: -4°F to 248°F [-20
°C to +120 °C]
>
Max. Ambient temperature 104°F [40°C]
>
Max. operating pressure 232/363 PSI
>
Protection class IP 55
Engineering presentation
Applications
>
Water Supply and Pressure
Boosting
>
Process water
>
Washing Systems
>
Industrial Circulation Systems
>
Cooling water
>
Irrigation
NEW!
* Available 2015
11/13
An Example of Over Pumping at Immanuel Lutheran School
Original Circulators replaced with Stratos 3 x 3-40
36
An Example of Over Pumping
Original Circulator
Stratos 3 x 3-40
7.5 H.P, 3 Phase motor
2 H.P, 230v, 1 Phase motor
Original pump drew 6426 watts
Circulator set to 25 feet of head.
Circulator ran 24/7 from October
1st to April 30th.
360 watts.
5040 hours x 6426 watts =
32,387,468 w/h per season.
Pump history indicated head
setting could be lowered.
Set point lowered to 13 feet of
32,387,468/1000 = 32,387 Kwh. head.
32,387 x $0.22/Kwh =
$7,125 per season for ONE
circulator!
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
37
3
7Flow vs. Efficiency
Vermont Housing Authority
ECM pump vs. PSC
400
350
300
250
Outdoor
Temp
200
150
100
50
0
1
38
38
77 153 229 305 381 457 533 609 685 761 837 913 989
Powerpoint Title
•
•
•
•
•
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
39
Title – Department/Author (Insert > Header and Footer)
Month/Year
Any Questions?
40
Title – Department/Author (Insert > Header and Footer)
Month/Year
42
42
43
43
44
44
Cost of Parts
Vs
New Premium Efficiency
45
45
46
46
47
47
48
48