Simple Easy Low or No Cost Ways to Save Energy

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<ul><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 1/40</p><p>presented by</p><p>Jack Ames, P.E.</p><p>Problem Solving Engineer</p><p>www.SteamTraining.Comproviding</p><p>On-Site Customized Steam/HVAC</p><p>Maintenance Training So YourPersonnel Can Work Smarterjackamespe@aol.com</p><p>410-337-3721 (o) 410-961-2008 (c)Identifying Problems, Implementing Solutions &amp; Saving Energy For YOU!</p><p>Call Me!</p><p>Simple Easy Low Cost/No Cost</p><p>Ways to Save Energy</p>mailto:jackamespe@aol.commailto:jackamespe@aol.com</li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 2/40</p><p>1. Walk, Listen, Observe.</p><p>2. Make sure that what should be offis really off.</p><p>3. Equipment you can probably turn off forever.</p><p>4. Use tight sealing automatic control dampers.</p><p>5. Use ultrasonic leak detectors to find leaks.6. Use self-contained temperature control valves</p><p>with integral sensors.</p><p>7. Use brush seals in raised floors of computerrooms.</p><p>8. Eliminate three-way valved bypasses on all steamtraps.</p><p>15 Low Cost/No Cost Ways to Save Energy</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 3/40</p><p>9. Test steam traps often.10. Use electronic data loggers.11. Replace missing or failed piping insulation.12. Make your energy management system (EMS)</p><p>work harder for you.13. Take a hard look at large buildings with verysmall steam heating loads.</p><p>14. Use steam powered float actuated sump pumps</p><p>to automatically remove water from steammanholes.</p><p>15. Have ongoing training for your maintenancepersonnel so they can work smarter.</p><p>15 Low Cost/No Cost Ways to Save Energy</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 4/40</p><p>1-A. Walk, Listen, Observe Once a week, before going to your office, walk through a different building. MBWA.</p><p> MBWA Degree: Management By Walking Areas.</p><p> Take pictures of possible ways to save energy with your digital camera.</p><p> Record sound bytes with each picture you take. Example: Why is cabinet unit heater in south vestibule of Lorton Hall running in July?</p><p> Send these pictures and notes to your staff persons who can investigate, report back to you,and make the necessary changes happen.</p><p> Visit your mechanical equipment rooms often. Are lights left on? Is anything running that does not have to be running?</p><p> Take pictures of anything that is out of the ordinary.</p><p> Example: Why is apparently defective 20 HP motor sitting on floor of MER 205 in Fox ChaseBuilding? Is this motor rally defective? How did it fail? Should it be rewound? Please have itremoved!</p><p> Once a month, visit your facility at night. Once a month visit your facility on a weekend.</p><p>Whats happening during off hours? When the cats away, the mice will play!</p><p> Keep good notes in a spiral bound notebook. Use a different notebook for each building for whichyou have responsibility.</p><p> Take an infra-red gun with you to easily find things that are hot or cold that should not be hot orcold.</p><p> Example: Failed or missing insulation on hot water or chilled water lines or cold</p><p>refrigerant lines.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 5/40</p><p>Use infra-red guns to find thingsout of the ordinary. Example: Whyis one 10 HP motor running 15oFhotter than another?</p><p>1-B. Walk, Listen, Observe</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 6/40</p><p>2-A. Make Sure What ShouldBe Off Is Really Off</p><p> Is outside lighting on during daylight hours?</p><p> Is a condenser water pump on a water chiller or a cooling tower fan operating eventhough the water chiller is shut down?</p><p> Are lights left on (not night lights) in offices, classrooms, shops, manufacturing areas,warehouse areas, etc., even through its after hours and nobody is there?</p><p> Are man cooler fans in maintenance shops still running after hours?</p><p> Are domestic hot water recirculation pumps running after hours when there is little or noneed for domestic hot water at that time?</p><p> Is your outdoor water chiller running even though it is 55oF outside temperature on anearly spring or fall morning?</p><p> Example: Outdoor water chiller at my church in Baltimore was running in late</p><p>September at 8:30 AM when it was 55oF outside. Outdoor thermostats are cheap.</p><p> Is your heating system still running in a maintenance, warehouse or manufacturing areaeven though large overhead doors have been wide open over 10 minutes? Doorswitches and elapsed timers are cheap.</p><p> Is steam still flowing to an air handling unit in a maintenance shop which has its fanturned off and which only needs to run in the very coldest of weather?</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 7/40Paragon OffDelay Timer</p><p>Spring WoundTimer</p><p>2-B. Make Sure What ShouldBe Off Is Really Off</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 8/40</p><p>2-C. Make Sure That ComputersAre Really Off When Not In Use.</p><p> Huge amounts of energy are wasted because employees do notturn off computers. Inexpensive or free software is available toturn off computers automatically at night and on weekends.</p><p> Computers running needlessly create significant airconditioning loads.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 9/40</p><p>3. Equipment You Can</p><p>Probably Turn Off Forever Unit heaters in mechanical rooms.</p><p>Unit heaters in electrical equipmentrooms.</p><p> Cabinet unit heaters in entry ways and</p><p>stairwells.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 10/40</p><p>The Problem</p><p> Conventional steel dampers can easily leak10% or more of rated air flow.</p><p> This causes:Artificial cooling loadsArtificial heating loads</p><p> Reduced effectiveness when using outside air</p><p>for free cooling</p><p>4-A. Use Tight Sealing</p><p>Automatic Control Dampers</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 11/40</p><p>4-B. Use Tight SealingAutomatic Control Dampers</p><p>The Solution</p><p> Test dampers for tight closure. If light is passing through whendamper is closed,so is air!</p><p> Check damper linkage to make sure it is operating smoothly. The bestlinkage is no linkage!</p><p>Use quarter turn direct connected damper actuators to minimize the useof linkage.</p><p> Use a separate damper to satisfy minimum outside air requirements.Do not introduce minimum outside air through the 100% outside airdamper used for free cooling.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 12/40</p><p>4-C. Leaking HVAC Dampers</p><p> When closed, are dampers really closed? Use flashlight test.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 13/40</p><p>5-A. Use Ultrasonic Leak</p><p>Detectors to Find Leaks Air leaks in compressed air lines and fittings. True for both high pressure process shop air and</p><p>20 PSIG pneumatic automatic temperature</p><p>control air. Failed or failing gaskets on walk-in coolers or</p><p>walk-in freezers. Air leaks in flex connectors on discharge side of</p><p>air handling unit fans. Air leaks at joints in supply air ducts, return air</p><p>ducts, and outside air ducts. Air leaks at disconnected flexible ducts.</p><p> Air leaks at flimsy access doors. </p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 14/40</p><p>5-B. Examples of Items that Leak</p><p>Compressed air fittings</p><p>Leaking access doors in ductworkDisconnected duct workFlexible ductwork connector</p><p>Loading dock loadlevelers and dock seals.</p><p>Walk-in coolers andfreezers</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 15/40</p><p>6-A. Use Self-contained Temperature ControlValves with Integral Sensors for Steam</p><p>and Hot Water Unit Heaters</p><p>The Problem</p><p> Steam and hot water vertical and horizontaldischarge unit heaters are often used to heatlarge open spaces such as maintenance shops,warehouses, and manufacturing areas.</p><p> Temperature control is usually achieved by wall orcolumn-mounted thermostats which simply cycleunit heater fans on and off.</p><p> When the fan is cycled off, steam or hot watercontinues to flow through the unit heater wastinghuge amounts of energy.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 16/40</p><p>6-B. Use Self-contained Temperature ControlValves With Integral Sensors for Steam and</p><p>Hot Water Unit Heaters</p><p>The Solution</p><p> Install self-contained temperature control valves with integral</p><p>temperature sensors.</p><p> These self-contained (no wiring required) valves will shut offsteam or hot water flow automatically when the temperatureset point is reached.</p><p> Use a strap-on aquastat on the condensate or hot waterreturn line to cycle off the fan when the control valve goesclosed to save even more energy.</p><p> Some condensate repiping may necessary on steam unit</p><p>heaters to ensure gravity condensate return. </p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 17/40</p><p>Ogontz TL Valve</p><p>6-C. Use Self-contained Temperature ControlValves With Integral Sensors for Steam and</p><p>Hot Water Unit Heaters</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 18/40</p><p>Ogontz TL Valve</p><p>6-D. Close-Up of Self-contained TemperatureControl Valves With Integral Sensors for Steam</p><p>and Hot Water Unit Heaters</p><p>7 A Use Br sh Seals to Red ce Conditioned</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 19/40</p><p>7-A. Use Brush Seals to Reduce Conditioned</p><p>Air Leakage in Computer Rooms</p><p>The Problem Most computer rooms and data centers have raised floors. Those raised floors provide a plenum to distribute conditioned air through</p><p>perforated tiles or supply registers in the raised floor.</p><p> This plenum also provides a place to run power and communication cablesto computer room equipment in a neat out of the way manner.</p><p> Large openings, typically 6 x 9 are field-cut in floor tiles to accommodatethese large, multiple, odd-shaped flexible cables.</p><p> Lots of conditioned air leaks out through these hard to seal cable openings,causing a loss of static pressure in the raised floor plenum. This makes it</p><p>more difficult to maintain the .7 1.0 inch static pressure recommended todistribute the conditioned air to where the heat producing equipment islocated.</p><p> To overcome this problem, many users install additional computer room airconditioning units to discharge more air into the raised floors. The realproblem is improper air distribution, not insufficient air</p><p>conditioning capacity. </p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 20/40</p><p>7-B. Use Brush Seals to Reduce ConditionedAir Leakage in Computer Rooms</p><p>The Solution</p><p>Use high quality brush seals to seal offthese numerous raised floor cableopenings.</p><p> Use similar brush seals to prevent air</p><p>leakage at the gaps where raised floorsabut computer room walls and wherecables penetrate computer room wallsbeneath the raised floor.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 21/40</p><p>8-A. Three-way Valved Bypasseson Steam Traps</p><p>The Problem</p><p> Human nature is flawed!</p><p> If something can be bypassed, it will be bypassed!</p><p> Bypassed traps typically stay bypassed. They look identical totraps that are operating properly.</p><p> A bypassed steam trap will waste 10 to 20 times as muchsteam as a wastefully blowing steam trap!</p><p> Sometimes the bypass valve will not reseat tightly when andif it is reclosed.</p><p> There are 16 additional potential leak points for everythree-way valved steam trap bypass.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 22/40</p><p>8-B. Eliminate Three-way Valved</p><p>Bypasses on Steam TrapsSolution</p><p> Eliminate three-way valvedbypasses on all traps.</p><p> They serve no useful purpose.</p><p>What piping items aremissing in this pipingschematic?</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 23/40</p><p>9-A. Blowing Steam TrapsWaste Huge Amounts of Steam</p><p>The Problem</p><p> A single passing high pressure steam trap can</p><p>easily cost you $5,000 a year in lost steam. Very few owners do steam trap testing.</p><p> Very few owners know how many traps they have;the makes, types and sizes; what they are serving,</p><p>and their locations.</p><p> Many traps are virtually inaccessible.</p><p> Occasionally, traps are buried beneath insulation.</p><p> Traps can only be tested when steam is ON! </p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 24/40</p><p>9-B. Test Steam Traps Often</p><p>The Solution Inventory your traps. Keep your inventory up to date.</p><p> This is time consuming and tedious but very worthwhile.</p><p> Test your steam traps frequently.</p><p>Ultrasonically Visually Steam Eye (automatic wireless system offered by Armstrong Steam)</p><p> In a large facility, consider having one person dedicated to suchsteam trap testing.</p><p> He can also test many other items such as bearings, compressed air</p><p>leaks, gasket leaks, etc. with the same ultrasonic tester. He can also do other testing such as vibration analysis. Do not use infra-red for testing traps; it only tells you whether traps</p><p>are hot or cold, not whether they are blowing. Watch out for oversized traps. They are huge energy wasters! Blowdown Y-strainers while testing steam traps. Use full port ball</p><p>valves. </p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 25/40</p><p>9-C. Test Steam Traps</p><p>Ultrasonically or Visually</p><p>Ultrasonic trap testing Visual trap testing</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 26/40</p><p>9-D.Test Steam Traps Often</p><p> Never use fixed orifice steam traps; theyare a rip-off!</p><p> Problems with fixed orifice/fixed Venturisteam traps</p><p> High first cost Typically no catalogued data No major trap manufacturers offer them They cannot be tested ultrasonically If undersized, they can easily cause dangerous,</p><p>costly water hammer Such traps properly sized could work on</p><p>constant loads but in reality constant loadsonly exist in textbooks.</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 27/40</p><p>10-A. Use Electronic Data Loggers</p><p> The first step in solving any problem is defining</p><p>exactly what the problem is. Data loggers help us define problems quickly and</p><p>easily in these ways: These small easy-to-conceal devices automatically monitor</p><p>whats going on over long periods of time when nobody ispresent.</p><p> Hook-ups are wireless. No external power is required.</p><p> No paper charts are required.</p><p> Downloading data to a computer is simple.</p><p> Interpreting data is simple.</p><p> They dont lie!</p><p> They are objective, not subjective.</p><p>What cant be measured cant be managed! </p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 28/40</p><p>10-B. Various Types of Data Loggers</p><p>Great for measuring</p><p>temperatures inspaces. Extremelycompact!</p><p>Great for measuring</p><p>temperature andhumidity.</p><p>Great for measuring temperature</p><p>and humidity. Built-in LEDsenergize if temperature or humiditygo below or above user set limits.</p><p>Measures AMP drawon motors and otherequipment.</p><p>Measures up to 8 differenttemperatures simultaneously.Great for air handling unitsand chillers.</p><p>Measures differential airpressure between variousspaces or between insideand outside of building.</p><p>10 C T i l D t L Di l</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 29/40</p><p>10-C. Typical Data Logger Display</p><p>Typical graph of downloaded</p><p>temperature data logger. </p><p>11 A Missing or Failed Piping Insulation</p></li><li><p>8/3/2019 Simple Easy Low or No Cost Ways to Save Energy</p><p> 30/40</p><p>11-A. Missing or Failed Piping InsulationWastes Huge Amounts of Energy</p><p>The Problem</p><p> Failed or missing piping insulation wastes energy.</p><p> If water gets inside insulation, it invariably fails.</p><p> Walking on insulated pipe lines is not uncommon and is never good forthe insulation.</p><p> Improper installation of insulation, especially on cold lines, can lead topremature failure.</p><p> One type of insulation definitely does not fi...</p></li></ul>