ENERGY SAVINGS POTENTIAL IN STEAM SYSTEMS. August 24 th, 2016

Transcription

1 ENERGY SAVINGS POTENTIAL IN STEAM SYSTEMS August 24 th, 2016

2 Overview 8:00 8:30 Pat Berger Intro & Heating System Rebates 8:30 11:00 Campbell-Sevey Energy Savings Potential in Steam Systems feature presentation 11:00-11:05 Pat Berger Trade Incentives & Closing 2 2

3 Introductions Xcel Energy Team Kate Berg Product Manager Pat Berger Trade Relations Manager Bruce Boerner Energy Efficiency Engineer Anna Crowley Marketing Assistant Campbell-Sevey Team Tom Pietsch Frank Kovacs Bob Lawrence 3 3

4 How CIP Programs Work Conservation Improvement Programs (CIP) Next Generation Energy Act of 2007 established energy savings goals for all natural gas and electric utilities that operate in the State of MN. Have been in existence in some form since Overseen by MN Department of Commerce Division of Energy Resources (DER) to ensure: 1. Ratepayer dollars are used effectively 2. Energy savings are reported accurately Energy savings goal of 1.5% of average retail sales for both electric and natural gas sales. Program budgets and energy savings are reported annually. 4 4

5 Rebate Program Basics Xcel Energy files a triennial plan with the DER every 3 years. Current plan covers Determines which programs will be offered and what the rebate levels will be. Update saving and rebates for current Energy Code. Programs are funded by ratepayer dollars, which are accrued from customer bills as part of the Resource Adjustment rider CIP portion of the Resource Adjustment rider is currently Electric - $ /kWh Natural Gas - $ /therm Solar and Wind programs are funded through a separate budget. 5 5

6 Rebate Program Basics Available to any Xcel Energy customer on a commercial/industrial rate Exception of CIP exempt customers (extremely large customers that do not pay the CIP rider on their bills) Electric rebates available to Xcel electric customers, natural gas rebates available for Xcel natural gas customers Xcel electric service: Twin Cities, Mankato, St. Cloud, Winona Xcel gas service: St Paul, Brainerd, Moorhead (north of the Mississippi river) 6 6

7 Programs Prescriptive Lighting Efficiency Cooling Efficiency Heating Efficiency Motors & Drives Efficiency Foodservice Equipment Fluid Systems Optimization Computer Efficiency Custom Custom Efficiency Efficiency Controls Study/Holistic Business New Construction Energy Design Assistance Energy Efficient Buildings Recommissioning Turn Key Services Fluid Systems Optimization Data Center Efficiency Process Efficiency Commercial Efficiency 7 7

8 Program Delivery Account Managers Assigned account reps for largest energy consumers Deal with everything from reliability and billing issues, to renewables and energy efficiency Typically for customers with 800+ kw demand or part of a larger organization (ie. Target, Walmart, City/County/State) Business Solutions Center Energy Efficiency Specialists Work with any business customer that doesn t have an assigned rep Work exclusively on energy efficiency. Work with smaller-mid sized business customers Trade Relations Managers Work with engineers, distributors, contractors, and manufacturers. Assigned by program (ie. Heating, Cooling, etc.) 8 8

9 Participation Requirements Install qualifying equipment Equipment must be installed and operational before rebate can be paid Complete rebate application Different application for each program Provide project cost documentation Rebate are capped at 60% of (incremental) project cost Costs can include installation, engineering, and labor costs Equipment specifications 9 9

10 Heating Efficiency Boilers Equipment Minimum Efficiency Rebate (per million BTUH) New Hot Water Boiler New Hot Water Boiler Replacement Hot Water Boiler 85% $800 92% $3,500 92% $7, Steam Boiler 81% $500 Over 10,000,000 BTUH must go custom Over 30% process load must go custom Under 300,000 BTUH must be ENERGY STAR Efficiency based on AHRI test conditions

11 Heating Efficiency Boiler Add-on Equipment Equipment Rebate Modulating Burner 1 $1,500/ MMBTUH 2 Outdoor Air Reset Control $200 / control 02 Trim Control 25% equipment cost 3 Stack Damper 25% equipment cost 4 Turbulator 25% equipment cost 5 1. Minimum 5:1 turn-down 2. $7,000/burner max 3. $5,000/boiler max 4. $250/damper max 5. $400/boiler max 11

12 Heating Efficiency Boiler Tune-ups Rebate of 25% of tune-up cost; maximum of $250/boiler Rebate can be received every other calendar year Rebate Requirements Adjust airflow and reduce excess stack temps Adjust burner and gas input, manual or motorized draft control Check adequacy of combustion air intake Check proper venting Check safety controls Clean and inspect burner nozzles and combustion chamber Clean heat exchanger surface when weather or operating schedule permits Complete visual inspection of pimping and insulation Measure combustion efficiency using electronic flue gas analyzer (MUST INCLUDE COPY OF COMBUSTION ANLAYSER TEST, NO HANDWRITTEN RESULTS) 12

13 Heating Efficiency Pipe Insulation For new or replacement insulation on existing piping. New piping not eligible for this rebate. Pipe Diameter R-Value Rebate $2 / linear ft / in pipe diameter $3 / linear ft / in pipe diameter $4 / linear ft / in pipe diameter 13

14 Heating Efficiency Steam Trap Audits $15 / trap tested, orifice traps do not qualify $30 / trap repaired/replaced, orifice traps do not qualify Eligible for audit rebate every other calendar year Testing rebates paid only if all traps tested are logged and documented AND all failed traps are repaired/replaced 14

15 Heating Efficiency Water Heaters Type Minimum Efficiency Rebate Storage 88% $200 / BTUH Tankless 88% $200 / BTUH Commercial Furnaces Minimum Efficiency Rebate 90% AFUE $100 92% AFUE $200 94% AFUE $250 96% AFUE $300 15

16 Motors & Drives Variable Frequency Drives 16 HP Rebate HP Rebate 1 $ $2, $ $3,000 2 $ $3,500 3 $ $4,000 5 $ $5, $ $6, $1, $7, $1, $7, $1, $8, $2,000 Rebate base on which is smaller; drive or motor HP

17 Custom Efficiency All inclusive catch all product For projects not covered by our prescriptive programs For equipment or process improvements Efficiency Controls is a custom type program Typical heating/natural gas projects seen through custom: Boiler/boiler tune-ups on boilers larger than 10,000,000 BTUH Boilers/boiler tune-ups on boilers with greater than 30% process load Heat recovery projects Process steam/hot water projects Preapproval is REQUIRED Rebates based on identified energy savings $400/peak kw $5/Dth 17

18 Custom Efficiency Submit Analyze Preapprove Implement Rebate Submit 1. Application 2. Worksheet 3. Scope 4. Costs Analyze Xcel Energy Engineers will conduct analysis to determine energy savings. Preapprove Project will be preapproved or rejected. If approved, proposed rebate amount will be included. Implement Customer completes and installs project. Rebate Submit final paperwork and rebate will be paid 18 18

19 Custom Efficiency Incremental Analysis Baseline case versus high efficiency case Assessing the incremental value Comparing the extra benefit with the extra cost Baseline case might be to buy new less efficient equipment Baseline case might be to do nothing 19

20 Custom Efficiency Key Considerations Project Cost All custom type projects must fall within 9 month 15 year simple payback window Operating Hours Use actual operating hours Utility Rates Use blended average that includes both demand and energy charges Baseline Assumptions Xcel uses baselines that have been approved by the DER 20

21 Efficiency Controls Custom type project Follows the same process as Custom Efficiency Different rebate application and worksheet from Custom Efficiency Same rebate levels as Custom Efficiency $400/kW $5/Dth For Building Automation System (BAS) type projects Typical projects are for upgrading from pneumatic to digital controls 21

22 Heating System Optimization Study Funding for engineering study of your entire heating system or system components to identify and quantify energy saving projects Funding based on expected energy savings Will fund up to 75% of study cost (max of $25,000) Rebate payment made upon study completion Study must be PREAPPROVED 22

23 Xcel Energy Energy Saving Potential in Steam Systems Looking for ways to improve your steam heating systems? Reducing waste in steam heating systems

24 4 Main Areas to Find Savings Opportunities 1. Generation 2. Distribution 3. Utilization 4. Condensate Return 5. Emphasis on Insulation Technology

25 Potential Steam Savings??

26 Typical Steam System STEAM DISTRIBUTION STEAM UTILIZATION BOILER ROOM CONDENSATE RETURN

27 Frank Kovacs 27

28 Heat Losses Regardless Before After 28

29 Insulation removal is the result of: Inspection, Service & Repair Bad Practices vs Best Practices

30 Example: Selling = 5 LF Pipe Energy Savings A history of neglect can be expensive. Example: 4 150# Gate Valve $ to $ / Year!

31 SAVINGS for BARE GATE VALVES FUEL COST $ / 1000# STEAM / 350 F Valve Size Cost Bare (Un-insulated) Cost Insulated Annual Savings # Gate Valve 8 150# Gate Valve 6 150# Gate Valve 4 150# Gate Valve 2 ½ 150# Gate Valve $ 2, / Year $ / Year $ 1, / Year $ 1, / Year $ / Year $ 1, / Year $ 1, / Year $ / Year $ 1, / Year $ / Year $ / Year $ / Year $ / Year $ / Year $ / Year 31

32 The Gate Valve SF equals Pipe Length SF 1 each Gate Valve = 5 LF of Exposed Pipe (Of Equal Size) Gate Valve Size Gate Valve SF Pipe Size (IPS) Equal LF of Pipe # Gate Valve 6 150# Gate Valve 2 ½ 150# Gate Valve 15.9 SF 10 IPS - Pipe 5.9 LF Piping 8.8 SF 6 IPS - Pipe 5.2 LF Piping 4.1 SF 2 ½ IPS Pipe 5.7 LF Piping 32

33 The Surface Area is Compelling! 10 each # Gate Valves = 59 LF Pipe 20 each 6 150# Gate Valves = 104 LF Pipe 30 each 2 ½ Gate Valves = 171 LF Pipe 60 each Bare Fittings = 334 LF Bare Pipe If it was bare pipe, it would be insulated! Why ignore the opportunity for savings! 33

34 Energy Survey Services with Infrared Measurements ( The Measurements are Real Time & Accurate! ) Before After 34

35 This Insulation Work is Brand New! Best Practices is Worst Practices! # Gate Valve Potential Annual Savings: $ We search for ALL bare surface conditions; Steam Valves, Fittings, Equipment and Pipe. 35

36 Energy Survey Services Finding Opportunities We search for Bare Fitting surfaces. We create a Laundry List of items. We Walk Through the steam system. We use Infrared Gun to obtain surface temperatures. We Survey bare Hot Surfaces. We insulate surfaces typically left untreated. 36

37 How many valves in the system? 37

38 We will.track & Follow The Steam System (Taking a Steam Systems Approach) With high quality CAD / CNC design we cover all hot surfaces! Boiler Rooms: Boilers DA Tank Steam Header HW Heat Exchangers Tunnels/Manholes: Service Shut-Off Valves Expansion Joints Drip Legs Main Mechanical Rooms: Main PRV Station (1/3 2/3) HW HX Control Valve Stations Penthouse Mechanical Rooms: PRV Stations Main Steam Supply Valves Pasterizing: HP Steam Valves / Fittings Condensate Return Paper Machines: Rotary Joints Flex Hoses Valves 38

39 Mechanical Room - Opportunities (6 Fittings) 1 each 4 150# Gate Valve 1 each 4 150# Sarco Strainer 1 each 2 ½ 150# 25P Spirax PRV 1 each 4 150# Gate Valve 1 each 3 300# Globe Valve Can t See Drip Leg Trap Assembly: ¾ Thr d-gv / STR / UN / Stm Trap ( Consider High Pressure Steam: Drip Legs & Threaded Fitting Assemblies ) 39

40 List of Fittings Upstream Piping to the Trap The Steam Trap (Make, Model, Type is helpful) Secondary Consideration: Down Stream Piping from the Trap Up-Steam Flow is most important Down Stream Flow is secondary, not important 40

41 Energy Survey Listing 2 each 1 ¼ Thr d Union 1 each 1 ¼ Thr d Spence PRV The PRV is a Standard Design The Union Blankets will match up to the Standard PRV Blanket 41

42 Post M&V (Measurement & Verification) Reports include: The Fitting, Tag#, Thermographic and Digital Photo Note the temperature drop! 42

43 PRESSURE REDUCING STATION After Before Before 43

44 CONDENSATE RECEIVER SKID PACKAGE After Before 44

45 Steam Pasteurizer & Condensate Return Design: LT500LFP-Heat Sealed Straps 45

46 8 150# Gate Valve 8 150# Strainer Before After 46

47 We Follow The Trap Survey 47

48 Typical Steam System STEAM DISTRIBUTION STEAM UTILIZATION BOILER ROOM CONDENSATE RETURN

49 Typical Steam System

50 Steam System Topics 1. Steam Traps 2. Importance of Regular Trap Monitoring 3. Automatic Trap Monitoring 4. Trap Insulating Blankets

51 Typical Steam System STEAM DISTRIBUTION STEAM UTILIZATION BOILER ROOM CONDENSATE RETURN

52 52 Steam Distribution Piping

53 53 Mud-Pots

54 High Velocity Hazards Velocity = 5,000 to 12,000 fpm Condensate flows in a wave pattern formed by friction of high velocity flash steam flowing over the water surface. If water level and/or velocity becomes to high, waves increase in size and fill pipe forming a piston of water traveling at high velocity. Collisions with pipe bends, ends and equipment produce destructive water hammer. 54 High line velocity also erodes pipes and bends and causes high back pressure

55 Trap Maintenance Cost Savings 55

56 Steam Trap Types Thermodynamic Thermostatic Mechanical 56

57 Steam Trap Types Thermodynamic Disc Thermostatic Wafer Balanced Pressure Bi-Metallic Mechanical Traps Inverted Bucket Float (and Thermostatic) 57

58 What a Steam Trap Must do to be Beneficial in a Steam System Handle Variable Loads Remove Condensate as it Forms Remove Air and Non-Condensable Gasses Resist Water Hammer Handle Light Loads Resist Freezing Damage 58

59 Operation of the F&T Steam Trap 1. Start Up (High Liquid and Air Load) 3. Drain Out (Normal Condensate Load) Caught Up (Final Air Pushed Out)

60 Operation of the Inverted Bucket Steam Trap 1. Start Up 2. Caught Up 3. Fill Back Up 4. Draw Out 60

61 Steam Trap Management Is Becoming Increasingly Important The value of steam Focus on energy savings and cost avoidance

62 Typical Steam System Program Issues of Today Facilities struggle to maintain focus on steam trap management because of other facility priorities Labor in most facilities is limited workers are asked to do more with less Tracking energy savings and cost avoidance on a continual basis does not exist due to lack of available tools

63 Physical Challenges Search and test all traps Sounds way easier than it is That s why Xcel provides trap survey rebates

64 What is Wireless Trap Monitoring? Radio Frequency 24/7 steam trap monitoring system designed to effectively allocate labor, and promote energy savings The trap population can be viewed from any computer in the company network When a steam trap reports as failed, action can be taken to mitigate losses and reduce additional steam system issues MSP Airport, General Mills, Fairview Southdale, 3M

65 Components of a Wireless Trap Monitoring System RF Transmitters - Measures cold and blow through conditions Repeaters - Where needed Gateway

66 Components of a Wireless Trap Monitoring System

67 Typical RF Facility Layout 1200 feet line of site Average distance is feet in most facilities

68 Energy Efficiency: Trap Maintenance Cost Savings 28 Bad Traps Found with ultra-sonic trap tester

69 Typical Steam System STEAM DISTRIBUTION STEAM UTILIZATION BOILER ROOM CONDENSATE RETURN

70 Potential Boiler Savings??

71 Steam Boiler Room Components Water Softener/Chemical Treatment Blowdown Equipment Boiler Feed Flue Gas Economizers

72 High Pressure Steam Boilers ASME Section I, Process Boiler Steam Boilers above 15 PSIG

73 High Pressure Steam Boilers Must Keep Water in the Boiler!

74 ON/OFF Feedwater Control vs. Modulating Feedwater Control Old Boilers - On/Off Control New Boiler - Modulating Control

75 Matt happened to be in the boiler room, thus, narrowly avoiding this potential boiler EXPLOSION!

76

77 Past Boiler Concerns Condensate lines are rotted out and are dangerous to be around. Liquid leaking to building floors is a problem. Boiler Explosion, past close calls of rupturing inner combustion tube.

78 Boiler Burner Short Cycling (Old Boilers) On / Off Burner (Pre-purge, post-purge losses) Standard burner turndown: 4:1 NG, 3:1 Fuel Oil Optional Turndown: 10:1 NG, 6:1 Fuel Oil

79 Tune Up Boiler Burner to Improve Combustion Efficiency Current boilers won t stay tuned because of inadequate boiler room make-up air.

80 Operating Boilers at Reduced Pressures

81 Vented Steam is Boiler Water Make-Up!

82 Water Softener Ion Exchanger designed to remove the calcium and magnesium ions and replace them with sodium ions. Twin alternating design allows for one tank to be on line while the other tank is regenerating or available as back up. Water Softeners still have leftover residue.

83 External Boiler Separator Steam Meter

84 Reverse Osmosis Reduce Total Dissolved Solids 98% or greater. Minimize Required Boiler Blowdown. Piping Materials after RO unit usually stainless steel. No Residue! GPM needed for Grain Millers

85 Bottom Blowdown High pressure boilers require two bottom blowdown valves piped in series. Code requires the first valve to be quick opening and the second valve to be a slow opening type. Low pressure boilers require only one blowdown valve. Quick Opening Slow opening

86 Automatic Surface Blowdown Continuous sampling motorized valve will open when conductivity (TDS) gets to high. Intermittent sampling also available.

87 Economizers Reduce Operating Costs Economizers lower stack temperatures Preheat boiler feedwater Increase boiler efficiency by 3-8% Reduce fuel consumption SAVES YOU MONEY

88 Boiler Feedwater Flue Gas Economizer

89 Steam Boiler Economizer Savings Data without Heat Recovery Performance with Heat Recovery

90 Condensing & Indirect Contact Economizers 3-12% Energy Savings

91 Condensing & Direct Contact Economizers 3-12% Energy Savings

92 Economizer Configurations Cylindrical Economizers Box Economizers Down the Stack Field Erected

93 Condensing Economizer (3-10%) HOT FLUE GAS SLIP STREAM FROM PRIMARY STACK BOILER MAKE-UP WATER OR LIQUID. PROCESS WATER, THERMAL FLUID, GLYCOL WATER CONDENSING ECONOMIZER FIBERGLASS STACK

94 THERMO CHARGING Go High Efficiency by Adding Economizer Surface Area High Efficiency Economizers can be obtained by: Adding another economizer to the existing economizer Replace the existing economizer with a larger one Considerations include gas pressure drop and space limitations

95 CONDENSING ECONOMIZER Boiler Efficiency of Condensing Economizers System Combustion Efficiency Stack 4% excess O2 Temperature F Boiler 78 to 83% 350 to with FW economizer 83 to 86% 250 to with FW and Condensing Economizer 90 to 95% 75 to 150

96 Installation Before & After BEFORE AFTER BEFORE AFTER Manufacturing Waste Heat Transfer Products to Save Energy

97 Questions/Thoughts? 97

98 Trade Partners

99 Join the Trade Partner Network Access to Trade Relations Manager Trade Relations Managers are like Account Managers for Trade Partners Can help you address any rebate or program questions that may arise Quarterly newsletter Energy Exchange Keep up to date on what s happening with Xcel Energy s energy efficiency programs. Receive s about events, trainings, and promotions Xcel Energy frequently hosts in person training and webinars that can help you build energy efficiency into your business. Stay informed about limited time bonuses and program promotions

100 Trade Partner Participation Commercial prescriptive and custom type rebate programs are open to participation from any Trade Partner Study type programs require that Trade Partners become qualified to deliver studies Trade Partners can participate in many ways: Complete rebate paperwork for your customers as a value added service Work with Xcel Energy to collect required project information for customer submitted rebates Incorporate rebates into project scope and bidding Quote lower project costs by receiving rebates directly Trade Incentives

101 Trade Incentive Basics Compensation for your time and energy Must include Trade Partner ID on project application to qualify Trade Partner ID can be issued to individuals or organizations Simple, one-time application process Name Company Contact Information W-9 (if annual trade incentives total over $600, it become reportable income) Paid at the same time as the customer rebate Equal to a percentage of the customer s rebate Does not take money away from the customer

102 Trade Incentives 102 Program Type - Amount Custom Any project 10% Cooling Chillers 10% Chiller VFD Retrofits 10% DX Units 5% DX Unit w/economizer 10% Heating Equipment 10% Boiler Tune-Up - $25/building Custom Any project 10% Data Centers Any project 10% Efficiency Controls Any project 10% Energy Design Assistance $4,000 - $12,000 project size Fluid Systems Optimization Prescriptive projects 10% Foodservice Equipment Any project 15% Motors & Drives VFDs 5% Recommissioning $2 / 1,000 kwh implemented 102

103 Contact Info Trade Relations Manger Patrick Berger Business Solution Center

104 Thanks for attending!