“energy conservation and the electronically communicated fan”€¦ · cisco expects...
TRANSCRIPT
“Energy Conservation and the Electronically Communicated Fan”
• Theory • Benefits • Application • A Typical Installation
Presented by: Ed Hegwood, LEED AP O+M, Program Coordinator HVAC and Energy Efficiency Red Rocks Community College / Rocky Mountain Education Center
United States Patent 3,525,385 COMPUTER REFRIGERATION SYSTEM Ralph C. Liebert,
Cisco expects "global data center traffic will grow threefold and reach a total of 7.7 zettabytes annually by 2017.“
By Steven J. Vaughan-Nichols for Networking | October 15, 2013
• zettabyte is a billion terabytes
7.7 zettabytes is equivalent to:
107 trillion hours of streaming music--about 1.5 years of continuous music streaming for the world’s population in 2017.
7.7 zettabytes is equivalent to: 19 trillion hours of business Web conferencing--approximately 14 hours of daily web conferencing for the world’s workforce in 2017.
8 trillion hours of online high-definition (HD) video streaming--about 2.5 hours of daily streamed HD video for everyone in the world in 2017.
Why are the Following Utilities
doing Prescriptive Rebates
for
Electronically Communicated
Motor Driven Fans
Electrically Commutated Motors (ECM) $350/kW
The Peak Demand Rebate program is a custom rebate program for medium to large business customers with the goal of obtaining on-peak summer electric demand reduction. It is designed to provide flexibility in terms of eligible measures (including lighting and HVAC). Rebates only apply to retrofits. Program participants provide verified electric demand savings through the installation of eligible DSM measures (energy efficiency and/or load shifting) in return for a $400 per kW incentive. Eligible projects must combine to a minimum 20 kW demand reduction during the summer peak period - defined as 3 to 6 p.m., Monday through Friday, from June 15 through September 15, excluding federal holidays. https://www.csu.org/CSUDocuments/busrebatesoverview.pdf
Custom Efficiency Colorado businesses earn rebates on energy-saving custom equipment With our Custom Efficiency rebates, you can: Earn rebates to offset the cost of energy-saving equipment and processes
Up to $400/kW of electricity saved and/or Up to $7/Dth saved for natural gas projects
Apply a wide variety of equipment and processes that are not covered under other rebates Lower your operating costs with energy-saving measures Note: Rebate amounts vary according to the project’s energy savings. http://www.xcelenergy.com/Save_Money_&_Energy/Find_a_Rebate/Custom_Efficiency_-_CO
All of these fans have the potential to be retrofitted to EC
Fans
Theory
How It Works
The EC fan has a DC (direct current) motor operating off of an AC (alternating current source). The EC (electronically commutated) brushless motor has permanent magnets in the rotor, which revolves around the outside of the motor.
How It Works
The EC motor behaves like a brushed DC motor as the speed under load is proportional to the drive voltage and the developed torque is in linear proportion to the current. The EC motor has a sensing and feedback circuit to ensure that the correct speed is obtained.
Benefits
Today Air is the Low Cost Way to Move Heat
• Dell warranties its servers for fresh-air cooling
solutions are capable of running at 104˚ degrees Fahrenheit for up to 900 hours per year and 113˚ hours Fahrenheit for 90 hours per year.
Airflow Efficiency
This metric characterizes overall airflow efficiency in terms of the total fan power required per unit of airflow. Total Fan Power (W) / Total Fan Airflow Cubic Feet per Minute (CFM) 1.25W/CFM (Standard) Exiting CRAC/CRAH
Units
0.75 W/cfm (Good)
0.5 W/cfm (Better) with EC Fans
Retrofit for Efficiency Improvements for Legacy Data Centers and other Commercial Buildings
What’s in it for You?
kW Reduction
Application
Forward-curved blades use blades that curve in the direction of the fan wheel's rotation. Efficiency is less than backward curved bladed impellers.
The backward curvature mimics that of an airfoil cross section and provides good operating efficiency with relatively economical construction techniques. Backward-curved fans are much more energy efficient than forward curved fans.
Replacing the existing forward curved fans with EC (electronically commutated), brushless motors and backward curved fans. Traditional fans are belt-driven which can absorb 5 to 15 per cent energy even when they are correctly installed, plus the cost of replacement and regular servicing. No belts also means no belt dust.
Value added maintenance savings are the removal of belts, fan shaft and bearings.
A further advantage of using these alternative fans, is the vastly improved airflow across the cooling coil. Most CRAC/AH unit existing fans are positioned just under the cooling coil, which causes three unnecessary issues: 1. FC fans block part of the coil, reducing the surface area and its efficiency. 2. The airflow has to split on either side of the FC fan, and then turn 90° before it can be
distributed.
3. Air for FC fans is distributed into the floor slab, causing turbulence and resistance, which uses up energy, EC fans can be located much lower down in the floor, thus removing the dead spots over the coil’s surface and reducing turbulence and resistance.
Forward Curved Fan EC Fan
17”
Reduced AIR
FLOW AREAS
Recirculation Zones
Level 3 DC -23 ea. Data Aire DA CRAC ←Customer Yellow = Inputs
Enter your total electricity cost ($/kWh)→ $0.075 Total Amps ↓ CFM For EC Fans→ 67 402,000
Enter the number of EC Fans needed (6,000 CFM Each @ .05")→ 67 50.61 Fan Utilization Factor 71.94% Voltage Voltage
Enter Cost per EC Fan to Retrofit Unit→ $2,732 Rated Fan Amps→ 19.6 Rated 480
Enter Motor Voltage→ 480 EC Fan CFM De-Rated Fan Amps 19.60 Actual→ 480
Enter % of Flow→ 60% 241,200 Actual Amps→ 14.1 Derate = 0.00%
Enter Number of CRAC/CRAH Units to be Retrofitted→ 23 Total Amps ↓ Corrected CFM 326,149
Existing Unit Total Fan Motor Current Amp Draw/ phase 14.1 324.30 CFM Correction→ 1.212
Enter Existing Unit Total Fan Motor POWER FACTOR → 0.85 CFM
Enter Existing Unit Total OEM Rated CFM → 11,700 Job Site CFM Alt Ft Correction
Existing Unit Fan Motor Utilization FACTOR 71.94% 234,628 4000 1.157
YOUR ESTIMATED ENERGY SAVINGS & PAYBACK kWh kW 4200 1.166
Annual Energy Spend Belt Drive FC Fan $150,390 2,005,198 228.90 4400 1.175
Annual Energy Spend EC FAN $27,359 364,788 41.64 4600 1.184
TOTAL ANNUAL SAVINGS $123,031 1,640,410 187.26 4800 1.193
TOTAL EC FAN UPGRADE COST $183,044.00 + TAXES 5000 1.202
EC FAN Maintenance COST Avoidance $4,600.00 $200/Unit 5200 1.212
ROI/ PAYBACK in Years 1.45 kW Saved 5400 1.222
Rebates @ $???./kW $74,905 187.26 5600 1.232
ROI/ PAYBACK with Rebates in Years 0.84 $400 < Rebates 5800 1.2426000 1.252
Fan Motor Heat Gain Reduction ( Increased Cooling to Floor) 622,167 BTUs-Cooling 6200 1.26
Total Capacity Made Available and returned to your Environment 273.69 Amps/phase Existing Retrofit 6400 1.268
Water Savings at Power Plant 623,356 Gallons / Year Fan W/kBTUs Fan W/kBTUs 6600 1.276
Carbon Dioxide Equivalent Avoided 2,460,615 Pounds / Year 69.86 12.71 6800 1.284
7000 1.292
W/CFM W/CFM
1.18 0.22
EC Fan Energy $ avings Calculator ©EE
Assumptions: 8760 Hour/Year Operation, 72 oF 35% RH. Energy Savings based on average EC fan modulation and
amp draw as identified
Disclaimer: Calculations are based on estimates and the assumptions shown above. While every precaution has been taken to ensure
accuracy and completeness, We assume no responsibility and disclaim all liability for damages resulting from use of this information or for
any errors or omissions.
$0
$20,000
$40,000
$60,000
$80,000
$100,000
$120,000
$140,000
$160,000
Annual Energy SpendBelt Drive FC Fan
Annual Energy SpendEC FAN
ENERGY COST COMPARISON
ABC Data Center
EC FAN Savings Points - EMERSON
• Energy Efficient EC fan savings up to 36% Variable Fan Speed Direct Air Path Lower Energy Consumption
• 16300 CFM
• 8.6kW
Blower System “A” Blower System “B” Blower System “C”
• 16400 CFM
• 6.9kW
• 16400
CFM • 5.5kW
jjjjjjjjjjjj
Efficiency The efficiency of the EC motor (typically > 90%) is higher than that of traditional asynchronous
AC motors (typically < 80%) and generates less heat, as there are no slip losses, less copper and
iron losses. The EC motor is also more efficient than alternative speed control methods including:
Inverter, AC frequency control, Triac voltage control, Multi-taped transformer voltage control (steps),
and Star/Delta switch (two step)0
The DC motor is inherently more efficient than AC motors and,
therefore, operates at a lower temperature putting less thermal
stress on windings and bearings, while also reducing the
amount of heat introduced into the air stream (lessening the
impact on “total” vs. “net” capacity of the CRAC unit).
+17,681
A Typical Installation
EC fan Install completed in “live”
DATA CENTER
67 FORWARD CURVED FANS AND MOTORS TO BE REPLACED
WITH EC MOTORS AND BACKWARD-CURVED FANS
Staging Area
Tech removing old motors and wiring
Tech removing old motors and wiring
Note: drop cloth on floor and organized tools
Old fans were palletized for easy
moving out of center
New EC fans ready for install
Three EC fans in place 30 Ton Unit
20 Ton unit , two fans installed 67 Fan Project Completed in Three Weeks
Pre-Project Measurements
6.30
8.15
5.94
7.98 8.27
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
CRAC Measured KW 10 day average at a constant air volume
Avg. KW
CRAC Unit Number 1 4 8 13 20
Post-Project Measurements
1.77 1.85 1.80 1.73 1.86
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
CRAC Measured KW10 day average at a constant air volume Avg. KW
CRAC Unit Number 1 4 8 13 20
KW Measurement Comparison
6.30
8.15
5.94
7.98 8.27
1.77 1.85 1.8 1.73 1.86 1.10
2.10
3.10
4.10
5.10
6.10
7.10
8.10
9.10
KW
Measu
rem
en
t
CRAC KW Measurement Comparison
Pre
Post
1 4 8 13 20
Actual KW Differences
Unit# 1 4 8 13 20
PRE 6.30 8.15 5.94 7.98 8.27
POST 1.77 1.85 1.80 1.73 1.86
Reduction-kW 4.53 6.30 4.14 6.25 6.41
This was a sampling of the overall project,
a total 67 Motors and fans were replaced.
110 kW total with more kW if fans are tied to server though put ***.
Fan Law (Cube Law): The motor power varies with the cube of the
motor speed. ***
Reduced Motor kW = Existing Motor kW x (speed2/speed1)3
10% Reduction
20% Reduction
Previous generations of servers may have used 400 watts but still consumed 60% to 70% of that power even without performing any useful work, according to John Stanley, senior analyst for data center technologies at the 451 Group. “We’ve improved energy efficiency a lot, and newer generations of 1U commodity servers are improving,” he said. “Now an idle server might only use 25% to 50% of [its] total power.” Next-generation servers will use only a fraction of their total power when idle and actively power off when unneeded.
Advantages of the EC Fan Imbedded Sensors in the Servers • The ultimate goal of this project and a
similar one conducted last year by Lawrence Berkeley National Labs*** is to link IT equipment directly to power and cooling systems, so that supply can be adjusted automatically to match demand.
***The project has been a success, The main
goal we had was to show that you could do this, that you could use the sensors in the IT equipment to control the building systems, and we achieved that," - Bill Tschudi, a program manager at Lawrence Berkeley. • The amount of energy saved will vary
depending on how efficient a data center is to begin with, he said. He predicted that most data centers would see a return on their investment within a year.
Bigger Air Handling Units
A rule of thumb is that for each degree you can reduce your condenser temperature, you will save about 1.5% on your cooling energy costs.
This diffuser is designed to recover this wasted energy by purposely and efficiently decelerating the flow and reducing swirl, boosting the pressure rise of
the impeller.
Aerodynamic efficiency and airflow is increased and acoustic noise is reduced.
Applications such as rooftop refrigeration condensers and heat exchangers can benefit from a dramatic noise reduction without sacrificing performance
Questions or Comments?
Thank you for Attending
Ed Hegwood
Office 303-914-6202
Cell-303-656-0374
www.rmecosha.com/HVAC
Water Efficiency in Commercial
Buildings
October 22,2013
24 x 7 EXCHANGE
Why does Denver Water care?
Reduce water & energy (heating) costs for our customers
Reduce operating costs (water treatment, pumping, chemicals)
Reduce wastewater discharge & costs Save potable water for expanding population ◦ Recycled and New Supply
Drought response
Developing a Water Budget
Indoor Uses ◦ Number of Residents, Employees, Fixtures
Outdoor Uses ◦ Irrigated Area, Vehicle Washing
Industrial Processes ◦ Cooling Equipment, RO systems, Cleaning
Water Budget
Indoor Water Uses Fixtures must meet standards set by Energy Policy Act of 1992
Fixture
EPAct of 1992 Standards for Plumbing Fixture
Water Use
Water Closets (gpf) 1.6
Urinals (gpf) 1.0
Shower Heads (gpm)* 2.5
Faucets (gpm)** 2.2
Faucet Replacement Aerators** 2.2
Metering Faucets (gal/cycle) 0.25
* When measured at a flowing water pressure of 80 pounds per square inch (psi).
** When measured at a flowing water pressure of 60 pounds per square inch (psi).
On the market since late 1980s
After initial opposition
◦ IPC accepted waterless urinals in 2006
◦ UPC accepted waterless urinals in 2009 – BUT water still has to be piped to the urinal & capped off
Issues: smell, clogged drain lines, maintenance staff training
New Waterless Urinal test at Denver Water
Waterless Urinals: The Debate
Viable alternative to domestic water
Not always available in all areas
Water quality does not meet federal drinking water standards
Recycled Water
Commercial Indoor Rebates Multi-Family/Commercial Multi-Tenant Sub-Metering $40
High Efficiency Urinal $100
Commercial Warewashing Equipment $300
Cooling Tower Conductivity Controller $500
Cooling Tower Make-Up or Bleed Meters $50
Coin/Card-Operated Laundry Equipment $150
High Efficiency Toilets $75
Flushometer Bowl/Valve Combination (1.28 gpf) $125
Commercial Outdoor Rebates
Weather-based Smart Controllers ◦ 25% of purchase price up to $2,500
Rotary Nozzles ◦ $2 per nozzle ($20 min and preapproval for >$2,500)
Evaluating Irrigation Efficiency Contracts
Commercial Incentive Program
Commercial, Industrial and Institutional customers can earn 50% of project costs up to $40,000 for improving the efficiency of their processes.
Earn $18.50 for every 1000 gallons of water saved over a one-year period.
Must meet a minimum savings requirement of 100,000 gallons per year to qualify.
Holds customer accountable
Paying for results
Versatile
Allows for long-term savings component
Performance Based Contracts
Past Projects
Hospital sterilizers
RO for vehicle washing
Replace water-cooled compressor
Re-circulating water to cool commercial washing machines
Add Ozone treatment to laundry facilities
Cooling Processes
Eliminate single-pass cooling ◦ Often associated with equipment cooling for pumps, compressors, ice machines, air conditioners, etc.
Replace water-cooled with air-cooled models
Identify opportunities to capture process water for reuse later
Using Reuse
• In-plant “used” water
• Softener rinse
• RO reject
• Boiler blowdown
• Condensate
• Gray water
• Even cooling tower blowdown with pre-treatment
Cooling Tower
Incentive Program
Presented by
Rick Alvarado
Conservation Tech II
Cooling Tower Incentive Program Director
Denver Water
Cooling Tower Incentive Program
• Commercial, Industrial and Institutional customers can earn 50% of project costs up to $40,000 for improving the efficiency of their processes.
• Earn $18.50 for every 1000 gallons of water saved over a one-year period.
• Must meet a minimum savings requirement of 100,000 gallons per year to qualify.
Incentive Program Requirements
• Make-up and blowdown meters
• Controller capable of monitoring tower conductivity
• Communications package allowing for monthly reports to Denver Water
Water Conservation
• Increase cycles of concentration • Quickest method of water conservation
• No downtime
• Consult a chemical supplier
Cycles
5
8
Savings
Makeup water
15 gpm
10,800 gpd
3,942,000 gpy
13.75 gpm
9,874 gpd
3,604,000 gpy
1.25 gpm
926 gpd
338,000 gpy
$1,000/year @ $2.96/1000 gal
Example—800 Ton HVAC Tower
Blowdown water 3 gpm 2,160 gpd 788,400 gpy 1.75 gpm 1,234 gpd 450,514 gpy 1.25 gpm 926 gpd 338,000gpy $659/year @ $1.95/1000 gal
Assume: average 25% heat load, 24 hour/day, 365
Total Savings: $1,659/year + chemical costs +
$7,260 incentive
Water Treatment Programs
• Traditional chemical treatment
• Green chemical treatment
• Physical water treatment
Traditional chemicals
• Corrosion inhibitors (polysilicates, phosphonates, azoles, etc.)
• Scale inhibitors (phosphonates, polymers)
• Fouling control (filtration, dispersant & fluidizer polymer chemicals)
• Microbio control (chlorine, bromine, ozone, H2O2)
Green Chemical Treatment
• High-bonding crystal modifiers
• Originally developed for lead poisoning
• Typically biodegradable & biorenewable
• Reduce blowdown by 90%
• Zero-blowdown possible
Cycles
5
40
Savings
Makeup water
15 gpm
10,800 gpd
3,942,000 gpy
12.3 gpm
8,860 gpd
3,234,500 gpy
2.7 gpm
1,940 gpd
707,500 gpy
$2,094/year @ $2.96/1000 gal
Example—800 Ton HVAC Tower
Blowdown water 3 gpm 2,160 gpd 788,400 gpy 0.3 gpm 220 gpd 80,900 gpy 2.7 gpm 1,940 gpd 707,500gpy $1,380/year @ $1.95/1000 gal
Assume: average 25% heat load, 24 hour/day, 365
Total Savings: $3,474/year + chemical costs +
$15,198 incentive
Physical Water Treatment
• A non-chemical method of water treatment for the purpose of scale prevention or mitigation
• Typically electromagnetic solenoid coils
Physical Water Treatment
• Pulsed low (60 Hz) &
high (10-100 kHz)
frequency EM fields
Source: Clearwater Systems
• Electrolysis produces a high potential for scaling
• Eliminates chemical handling
• Cathodic reaction:
Non-Chemical Water Treatment
OHCOCaCOOHCOCa
OHHeOH
223
2
3
2
2
_
2
2
222
Cooling Water System Audit (2009)
• 113 towers – average 4 cycles
• Uncontrolled water leaks
• Overflow of basins
• High tower drift
• No metering
• Little testing
• Inoperative controllers
Denver Water’s
Recycled Water Quality
• Conductivity 360-1250 micromhos
• Calcium Hardness 40-70 CaCO3
Action Plan for Facility Engineers
• Get information about your system
• Look for leaks
• Determine cycles of concentration
• Find out how much water is being used
• Meter your system!
• Insist on higher cycles
• Documentation
• Wastewater Credits
Cooling Tower Incentive Program
Getting Started • Choose a project that will improve water-use
efficiency or make use of reuse.
• Contact Denver Water for a pre-installation visit and inspection.
• Denver Water will issue a contract detailing the terms of the project.
• A Conservation staff member will conduct a post-installation inspection to verify operation.
• Denver Water will track your water use and issue quarterly reports.
• After a year of monitoring, Denver Water will issue a check for the amount of water saved.
• Contract between Denver Water and customer
(non-SFR), in which Denver Water pays the
customer for actual water savings achieved as a
result of the customer making water
efficiency/conservation changes to their tower.
What do we mean by
performance-based contract?
Free Audits: Indoor
• Determine water use
• Check meters
• Check for leaks
• Install low-flow features
• Identify maintenance issues
• Identify conservation opportunities!
43
Largest indoor water use
25% of total
Free Audits: Outdoor
44
• Visual inspection
of each zone
• Discover leaks,
breaks,
maintenance
issues
• Scheduling
Recommendations
• Identify efficiency
opportunities
Adjusting your irrigation schedule
monthly can save 30% of the water
used to irrigate every year.
The Importance of Maintenance
Contact
Rick Alvarado
Conservation Tech III
Office 303-628-6470
Cell- 303-994-6787
Denver Water
1600 West 12th Avenue
Denver, Colorado 80204
www.denverwater.org
www.denverwater.org