Slide 1

Slide 2

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

Slide 19

18 Stratos Performance Charts Advanced Stratos session18

Slide 20

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?

Slide 40

Slide 41

40

Slide 42

41

Slide 43

42

Slide 44

43 Cost of Parts Vs New Premium Efficiency

Slide 45

44

Slide 46

45

Slide 47

46