Big Ten Sustainability Conference November 15 16 2010

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Big Ten Sustainability Conference November 15 -16, 2010 Energy Efficiencies in Preventative Maintenance

Big Ten Sustainability Conference November 15 -16, 2010 Energy Efficiencies in Preventative Maintenance

Topics • Steam Trap Testing • Synchronous Drive Systems • Machine Alignment • Vibration

Topics • Steam Trap Testing • Synchronous Drive Systems • Machine Alignment • Vibration Program • High Capacity Filters Energy Efficiencies in Preventative Maintenance

Steam Trap Testing Problems with Steam Traps – 5% per year average failure rate

Steam Trap Testing Problems with Steam Traps – 5% per year average failure rate of the trap population – Live steam escapes to condensate system or drain line – Thousands of $$ wasted due to failed taps • At Penn State where the current billable rate for steam is $21. 59 per thousand pounds, a failed steam trap on a 15 psig steam line will waste $5800 per year Energy Efficiencies in Preventative Maintenance

Steam Trap Testing Methods for Checking Traps – Visual Observation – Requires test valve,

Steam Trap Testing Methods for Checking Traps – Visual Observation – Requires test valve, and the tester must know the difference between flash condensate and live steam – Sound Method – Ultrasonic listening device is used to listen to the action of the trap – Temperature Measurement Method – Temperature sensing device is used to measure the temperature differential on the inlet and outlet of the trap We have a testing crew at PSU Energy Efficiencies in Preventative Maintenance

Synchronous Drive System § What are they? § Notched or cogged sheave and belt

Synchronous Drive System § What are they? § Notched or cogged sheave and belt system § Used on supply and return fans 3 V-Belt Drive System Energy Efficiencies in Preventative Maintenance Synchronous Drive System

Synchronous Drive System Benefits of Synchronous Drives – Lower noise level (up to 19

Synchronous Drive System Benefits of Synchronous Drives – Lower noise level (up to 19 d. B) – Vibration reduced by as much as 19% – 98% efficiency rating (5% higher than typical v-belt drives) – Last longer than typical belts Energy Efficiencies in Preventative Maintenance

Synchronous Drive System Energy Benefit – Cost to operate 25 HP motor per year(24/365)

Synchronous Drive System Energy Benefit – Cost to operate 25 HP motor per year(24/365) with 3 V-Belt Drive and $0. 07 per KWH: $12, 496 – Cost to operate as above with Synchronous Drive: $11, 829 – Savings per year: $667 – Incremental Cost of retrofit - $850 – Less than 1. 5 year payback Energy Efficiencies in Preventative Maintenance

Machine Alignment Types of Misalignment – Parallel Offset – Angular Offset – Combination Parallel

Machine Alignment Types of Misalignment – Parallel Offset – Angular Offset – Combination Parallel and Angular Energy Efficiencies in Preventative Maintenance

Machine Alignment Contractor Installation (as found) – 40 Hp Centrifugal Pump Installation – 480

Machine Alignment Contractor Installation (as found) – 40 Hp Centrifugal Pump Installation – 480 Volt Electrical System – Combination of both Parallel and Angular Misalignment • 60 mils (0. 060 inches) Parallel Offset • 40 mils (0. 040 inches) Angular Offset Energy Efficiencies in Preventative Maintenance

Machine Alignment PSU Installation (after adjustment) – Both Parallel and Angular Misalignment Within Specification

Machine Alignment PSU Installation (after adjustment) – Both Parallel and Angular Misalignment Within Specification • 5 mils (0. 005 inches) Parallel Offset • 5 mils (0. 005 inches) Angular Offset – Measured 1 amp reduction on each leg at full load – Power Reduction ~ 831 Watts – Save 7, 282 KWh per year ~$500/year (less than 1 year payback) – Extends life of equipment Energy Efficiencies in Preventative Maintenance

Vibration Program • PSU Program currently monitors ~800 critical assets. – Chillers, cooling towers,

Vibration Program • PSU Program currently monitors ~800 critical assets. – Chillers, cooling towers, larger AHUs, exhaust fans and pumps • Benefits – Helps us transition from reactive to predictive maintenance by providing an early indication of machine failure. – Allows ample time to plan and coordinate an equipment shutdown instead of an emergency repair situation and the associated occupant inconvenience. – A minor benefit is reduced energy loss associated with vibration Energy Efficiencies in Preventative Maintenance

Vibration Program • Photograph of a vibration sensor (an accelerometer with an integrated wireless

Vibration Program • Photograph of a vibration sensor (an accelerometer with an integrated wireless transmitter and a mechanical vibration harvesting (piezoelectric) power supply mounted on a centrifugal chiller) Energy Efficiencies in Preventative Maintenance

Vibration Program Outdoor Wireless Receiver Indoor Wireless Receiver • Outputs monitored centrally • Real

Vibration Program Outdoor Wireless Receiver Indoor Wireless Receiver • Outputs monitored centrally • Real time actionable data available Energy Efficiencies in Preventative Maintenance

Air Filtration Evaluating a filter switch – Current standard: 2 inch pleated filter –

Air Filtration Evaluating a filter switch – Current standard: 2 inch pleated filter – New filter is a High Capacity 4 ply polyester panel filter • Higher initial cost: $2 per filter (24”x 24”) • Lower energy cost: $11 per filter per year • Lower pressure drop initially and over life – Reduces frequency of the change outs • Higher efficiency reduces coil fouling and improves heat exchange efficiency • Moisture resistant • Treated with biocide Energy Efficiencies in Preventative Maintenance

Energy Cost Comparisons One(1) 24”x 2” Pleated Filter Energy Consumption (KWh/Yr) Annual Energy Cost

Energy Cost Comparisons One(1) 24”x 2” Pleated Filter Energy Consumption (KWh/Yr) Annual Energy Cost CO 2 Emissions Saved (Lb/Yr) Standard Capacity 2, 361 $165. 27 0 High Capacity 2, 201 $154. 09 219 Energy cost calculation assumptions: 24/7/365 operation, $0. 07/KWh energy cost, System air Flow is 2, 000 cfm, Fan/Motor/Drive efficiency total 58% Standard Capacity Filter Average d. P (0. 665 in H 2 O) High Capacity Koch XL 8 -HC Filter Average d. P (0. 62 in H 2 O) CO 2 Emission: National average emission factor for electricity is 1. 37 Lb CO 2 per KWh Energy Efficiencies in Preventative Maintenance