Stratos Energy Savings Examples November 2008

Transcription

1 Stratos Energy Savings Examples November 2008

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3 Heat Supply Components Pump Location

4 System Piping SUPPLY CHECK VALVE ZONE PUMP BY-PASS BOILER RETURN BY-PASS CONFIGURATION WITH ZONE PUMPS

5 Does System Flow Change Is it a Pump or a Circulator? Both only one thermostatic thermostatic valves are valve open is open Head H [Ft] intersecting point = new operation point Flow Q [USGPM]

6 Speed Control Electronic continuous speed control (Constant Pressure) > Automatic differential pressure control Pumping Head H [Ft] H 2 H 1 n max 3 2 non-regulated pump 1 1. The sensor determined the actual pumping head. (actual value) 2. The electronic discerned the difference between the set value (point 1) and the actual value. (point 2) 3. The controller reduced the speed and moves the pumping head at the actual value now. (point 3) Q 1 Q 2 Volume Flow Q [USGPM]

7 Delta PC vs Delta Design Flow Design Flow is 42 Usgpm or 420, deg F t Delta PC or Constant Pressure (differential) low head systems Delta PV or Pressure Variant (max head twice min) high head systems BHP = H (Ft) x Q (Usgpm) H Constant Speed Curve Eff (0.?) x 3960 Assume Constant 70% 40 Designed Flow Friction Loss Curve 35 Ft x 42 Usgpm Operating Point BHP Design = = x Δpc Actual System Curve 25 Ft x 63 Usgpm Operating Point BHP Actual = = x 3960 Δpv 10 BHP pc = 25 Ft x 42 Usgpm 0.7 x 3960 = Ft x 42 Usgpm BHP pv = Flow (USGPM) 0.7 x 3960 = 0.33

8 Delta PC vs Delta 50 % Design Flow Design Flow is 21 Usgpm or 210, deg F t Delta PC or Constant Pressure (differential) low head systems Delta PV or Pressure Variant (max head twice min) high head systems 50 % System Curve Operating Point H Constant Speed Curve 40 Design Flow Friction Loss Curve Operating Point 30 Δpc 20 Δpv Flow (USGPM) BHP = H (Ft) x Q (Usgpm) Eff (0.?) x 3960 Constant Speed Eff Reduced BHP Design = 35 Ft x 42 Usgpm 0.7 x 3960 = 0.53 BHP 50 % = 41 Ft x 21 Usgpm 0.5 x 3960 = Ft x 21 Usgpm BHP pc = = x Ft x 21 Usgpm BHP pv = = x 3960

9 Delta PC vs Delta 25 % Design Flow Design Flow is 10 Usgpm or 100, deg F t Delta PC or Constant Pressure (differential) low head systems Delta PV or Pressure Variant (max head twice min) high head systems H % System Curve Operating Point Constant Speed Curve Δpc Design Flow Friction Loss Curve Operating Point BHP = H (Ft) x Q (Usgpm) Eff (0.?) x 3960 Constant Speed Eff Reduced BHP Design = 35 Ft x 42 Usgpm 0.7 x 3960 = 0.53 BHP 25 % = 43 Ft x 10 Usgpm 0.4 x 3960 = Δpv Flow (USGPM) BHP pc = 25 Ft x 10 Usgpm 0.7 x 3960 = 0.09 BHP pv = 13 Ft x 10 Usgpm 0.7 x 3960 = 0.04

10 Williams Lake School Williams Lake, BC

11 Williams Lake School Williams Lake, BC Power Consumption Estimates Constant Speed Pumps vs ECM New Project P1 Hp ratings from pump selection software (Blue Angel Load Profile) Full Load 10%, Partial Load 15%, Low Load 44%, Setback 35% Hp KW Hrs Hp KW Hrs KW Hrs Service GPM Head Control P1 Stratos Annual Std Annual Difference Leaving Furnace Rm ' Delta PV & LON Rad & Coil ' Delta PV & LON Lunch Room/Dorm ' Delta PV & LON Ind Arts ' Delta PV & LON Boiler Room 200 6' Delta PV & LON Gym ' Delta PV & LON Rad Addn ' Delta PV & LON Coil Addn 33 15' Delta PV & LON Office 21 36' Delta PV & LON Ent Furnace Rm ' Delta PV & LON P10 (New) ' Delta PV & LON P11 (New) 52 12' Delta PV & LON P12 (New) 52 12' Delta PV & LON Tot Annual KW Usage Heating Days Heating Hrs/Day Annual Heating Hours Annual $ Saving $7, Savings based on Years $72,841 Enter KWh Cost Here Enter # of Years Here

12 Frisco School Maine, USA Power Consumption Estimates Constant Speed Pumps vs ECM New Project P1 Hp ratings from pump selection software - Customer supplied load profile - Service GPM Head Control P1 Stratos Annual Std Annual Difference boiler circ ' w.g const. flow control load-side circ w.g integral speed control HX circ. 8 8' w.g temp dependant speed control entire circ. 8 8' w.g integral variable speed controller boiler circ ' w.g temp based speed control high temp loop circ. 9 15' w.g integral variable speed controller radiant slab 45 30' w.g integral variable speed controller boiler circ ' w.g const. flow control boiler circ ' w.g integral variable speed control Tot Annual KW Usage High Load 1448 Low Load 4848 Annual # Saving $5,796 Total 6296 Savings based on Years $57,958 $/Kwh 0.17 # Years 10

13 Old Artisan Heating Project New York, New York New 11,152 sq ft heated area, school for Autistic children Original Pump Specification > Three 7 ½ Hp, 250 Usgpm at 70 TDH, constant speed in-line pumps > Amperage (measured) 14 Amps Retrofit ECM Pumps > ECM in-line pumps, SET AT 13 TDH! > Amperage (averaged) 2.0 Amps > Operating at 340 Watts about ½ Hp Customer Comments > Much better comfort due to the ability of controlling the system, hot and cold spots have been eliminated. Recorded Amperage/Energy Savings (based on $0.20 per Kwh, 5040 Hrs/annum) > Original pump 2327 Watts/Hr/1,000 x 5040 Hrs x $0.20 = $2, per year for power > New ECM pump 360/Hr/1,000 x 5040 Hrs x 0.20 = $ per year > Annual savings $1,982.74! One Pump! Times three!

14 Maplegrove Co-operative Apartment Moncton, NB

15 Maplegrove Co-operative Apartment Moncton, NB 52 Unit, 6 story, multi-unit residential, conventional hot water heating system Heating Plant > Original oil fired forced draft hot water > New boilers installed high efficient, condensing, natural gas type, balance of system not upgraded Pumping Equipment > Existing 5 Hp, three piece inline type, constant speed > New pumps installed, ECM type operating in parallel, constant pressure setting, setback enabled Benefits > No zone valve failures (no excessive pressure during low heat demand periods) > No water hammer no pressure by-pass valve Customer Comments > This pumping technology is amazing, now we can rent the apartment unit above the boiler room because it is so quiet. The old pumps would make an awful racket. The electrical savings will pay for the installation of these two pumps in less than two years. Recorded Amperage/Energy Savings (based on $0.08 per Kwh) > Original pumps average 10 Amps, 6 month heating season, 24 hrs/day, 230 volt power > Annual operating cost - $ > New pumps average 0.9 Amps, 6 month heating season, 18 hrs/day (auto setback, priority DHW etc) > Annual operating cost - $54.00 > Annual savings $ ($7, over 10 years not including service/repair and energy cost increases) > Will power costs go up? > System condenses and there is a MINIMUM of 20 deg F across the boilers!

16 Variable Speed Pumping Why use VFD s? GREEN! 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 Positive displacement (usually piston or screw types) account for 27% Over 95% of all pumps are oversized due to multiple butt covering! Up to 80% 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!

17 IEA (International Energy Agency - Facts and Figures) Factoids on European Heating and Energy 78% of household energy costs is heating the home 90% if DHW (domestic hot water) is included 120 million heating pumps running in Europe 60,000 giga watt hours annually! According to IEA, ECM technology has a potential of 70% savings 42,000 giga watt hours annually Equal to all washing machines and dishwashers in all Europe North America Assume 3 million circs sold annually Average circ life 10 years Wattage per circ 100 Watts Totals 3 BILLION watts of power Smart pump technology reduces power consumption by 2/3! Does not include systems savings Does not include all other larger pumps

18 Life Cycle Costs (LCC) Return on Investment Real costs of pumping stations 60 % 50 % 40 % 30 % 20 % Purchase price Maintenance Energy costs Building & System costs 10 % 0 %

19 Start VFD Assessment New Systems Need to vary duty continuously Yes VFD potentially useful No Consider fixed speed pumps, On-Off control, Multiple sizes, etc. Mostly friction? Yes VFD potentially useful No Check overall benefits including non-energy items ie: reduced maintenance cost Calculate total annual operating cost with alternative system solutions Does the pump run most of the time? No Is VFD suitable? No Use fixed speed pump(s) Yes Yes VFD almost certainly beneficial Go to VFD Selection

20 Start VFD Assessment Retrofit Systems Is duty variable No Confirm existing fixed speed pump is correctly sized No Consider modification or replacement of equipment Yes VFD potentially useful Yes Retain existing installation if efficient Mostly friction? No Check overall benefits including non-energy items ie: reduced maintenance cost Yes VFD potentially useful Calculate total annual operating cost with alternative system solutions Does the pump run most of the time? No Yes Is VFD suitable? No Yes VFD almost certainly beneficial Are existing pump and motor suitable for proposed VFD Yes No Go to VFD Selection

21 Application Drawings (Click immage to access pdf drawings) 21 Wilo-Stratos - The High Efficiency Pump.

22 WILO Small Wet Rotor Circulators ECM Smart Automatically Controlled Circulators Eco 16 FX & BFX Model Stratos ECO Cast Iron (Available 1 st Quarter 2008) ECM (Electronically Communicated) technology Smart pump adjusts flow to system changes Auto setback Anti-seizing feature Easy wiring quick connectors Easy set-up (set p-v in feet of head via red button) Interchangeable with all competitors (F and FX flange types) Replaces 12 competitor s types 115 and 230 volt, models, cast iron & bronze Max temp 230 deg F, min temp 60 deg F Maximum wattage 59, minimum wattage 5.8 (@ 115 volt) Class A energy rating Eco 16 F Model

23 Stratos vs Stratos ECO Field of application Stratos (max 285 Usgpm) Large Residential / Commercial buildings Stratos Eco (max 14 Usgpm) Residential and Secondary System Applications Temperature range +14 F to +230 F +60 F to +230 F Field of application Operating concept Communication capability Control / operating modes Heating, AC, Solar, Geothermal, Extensive: Red Button (IR-Monitoring / LC-Display) Communication compatible for BMS p-v, p-c, p-t, Auto Setback Heating Simple: Red button 3-16 Ft Not Av p-v, Auto Setback

24 WILO Commercial Wet Rotor Circulators ECM Smart Automatically Controlled Circulators Stratos (Cast Iron Only) ECM (Electronically Communicated) technology Soft start high torque permanent magnet rotor 8 Models available interchangeable with Top S Smart pump adjusts flow to system changes ( p-v, p-c and p-t) Temperature control for condensing boilers Auto setback fuzzy logic Non-volatile memory no battery required Standard industry flanges 1 ¼, 1 ½, 2 & 3 Cataphoresis coating Interface modules for 0-10Vdc, LON and external control Dual pump mode (lead/lag, primary/secondary and back-up) Infrared service/diagnostic tool available Power consumption data logging Ability to lock out red button Single page start-up manual 230 volt +/- 10%, single phase (2 x 115, 230/1, 230/3 all OK) Overload protection (voltage, dry run, locked rotor, over temperature) No external sensors Class A energy rating

25 Stratos Documentation

26 WILO History Wilo international: Foundation of own subsidiaries abroad Foundation of Wilo-LG Pumps Ltd. Korea Foundation of the company Messingwarenfabrik Acquisition of the Louis Opländer French pump Maschinenbau manufacturer Pompes Salmson In-house electronics production, Dortmund Acquisition of the EMU group, Hof/Bavaria Acquisition of Mather & Platt, India

27 Production & Sales Light Assembly and Sales Worldwide. More than 50 companies worldwide in Europe, Asia, America and Africa with headquarters in Dortmund Approx. 6,000 employees Sales amounting to more than 870 m Euros

28 Innovations Large ongoing investment in Research and Development 3% of sales ($40M USD in 2007) > 250 Employees in 6 locations Continual upgrading of all manufacturing processes SAP implemented 2004 Global industry leader in product and market innovation > 20 Patent registrations annually > 120 running projects > 1 st circulating pump for heating applications > 1 st multi stage high pressure pump with wet rotor motor > 1 st high efficiency pump Ongoing evaluation of quality control and technical processes

29 Innovation First circulation accelerator in the world Introduction of the first completely oil-filled motor First fully electronic circulation pump First multistage glandless high pressure centrifugal pump in vertical construction First submersed mixer with three blades Introduction of CERAM coatings on wastewater and sewage products First sewage submersible motor with hermetically closed cooling circuit First high-efficiency pump in the world

30 WILO Namex Product History NR Stainless Subs Limited IPL Pumps Star 30 & 17 Class H Top S Pumps Added Borehole and 8 Subs Stratos ECO Z15 Top Z MVIS Limited Star Pumps Launched Class F Top S MVI Pumps IL Check Flange Stratos Star F June 2004 Feb 2005 Aug 2005 Sept 2005 Feb 2006 Aug 2006 Sept 2006 Oct 2006 July 2007 Sept 2007 Sept 2007 Sept 2007 Nov 2007 Jan 2008

31 Product families and figures (USA Canada) Product Examples Preformance Range Features & Benefits Features & Benefits Con t Small Circ WILO Star 1-38 USGPM 0-32 Ft Stainless Steel Shaft Wiring Terminals Steel Terminal Box Interchangeable Ultra Quiet No Mechanical Seals Check Flange Innovation Automatically Vented Big Circulator TOP S USGPM 8 70 Ft Cast Alunimum Terminal Box Threaded NPT Electrical Cataphoresis Coating 2 Speed all Voltages Short Flange to Flange ¼ Gauge Tappings Automatically Vented 23 Models (widest commercial wet rotor range in industry!) Pumps IPL USGPM Ft Standard NEMA Baldor Motors Cataphoresis Coating SAE Bolts (Metric Free) Short Flange to Flange ¼ Guage Tappings Tapped Pump Legs 1 Piece SS Stub Shaft Pumps IL USGPM Ft Standard NEMA Baldor Motors Bronze and Cast Iron Impellers Custom Impeller Trims Intergral Inlet Diffuser Backout Screws ¼ Guage Tappings 250 PSI Volutes Various Seal Options Stratos USGPM 3 40 Ft ECM Motor Technology Adjusts to System Demands No External Sensors Easy to Set up Built in Temp Seneor Interface Modules Self Diagnostic Infra-red Device

32 Product families and figures (USA Canada) con t Product Examples Preformance Range Features & Benefits Features & Benefits Stainless Steel Submerible USGPM Ft Heavy Stainless Steel Const Built in Check Valve 304 SS (Std), 316 Available 4, 6 and 8 Available Franklin Electric Motors 1/3 to 75 Hp Borehole Turbines US Ft CI and Cast Bronze Av Up to 150 Hp Av Heavy Duty Construction Immediate Deliveries Franklin Electric Motors Water Supply MVI USGPM Ft Std NEMA Baldor Motors No Shaft Height Settings 304 & 316 SS Available Interchangeable Seal Location Eliminates Air Locking By Pass accessory available Vertical Multi- Stage (wet rotor version) Available in October!

33 Radiant Heating Opportunities - Think A consumer survey revealed that consumers selected an HVAC service company to perform work based on: Reputation 70% Hours of service (24 hr) 7% Lowest price 13% Brand recognition (franchise) 10%

34 Questions / Comments?