1 PRESENTATION BY: MIKE BURT AIR FILTER SOLUTIONS INC. DENVER, COLORADO
2 INEXPENSIVE RETROFIT DESIGNS FOR ABOVE CEILING UNITS Fan coil units Fan terminal units Single ducted fan powered units Heat pump units Where air filtration applications are difficult to perform service install / change-out
3 WHY WOULD A RETROFIT TO THE FILTER SECTION BE NECESSARY? Where the existing application has a poor quality air filter in place. Where the existing application has a poor quality or broken down holding mechanism to hold the air filter in place.
4 FAN POWERED BOX
5 FAN POWERED BOX
6 FAN POWERED BOX
7 FAN POWERED BOX Wire holding filter in place
9 This 24X24X1 Poly Filter is bowing inward at only a velocity of 300 FPM or another words 1200 CFM
11 Air Flow verses Pressure Drop Filter Size: 24X24 More surface area = greater dust holding capacity = longer life Different Filter Types w.g CFM 300 FPM w.g CFM 400 FPM w.g CFM 500 FPM Amount of Surface Area MERV 1" Poly Framed Filter * not rated 4 sq. ft. 5* Camfil Farr Aeropleat III 1" Pleated sq. ft. 8 Camfil Farr Aeropleat IV 1" Pleated sq. ft. 8 Camfil Farr 30/30 1" Pleated sq. ft. 8 2" Poly Framed Filter * sq. ft. 5* Camfil Farr Aeropleat III 2" Pleated sq. ft. 8 Camfil Farr 30/30 2" Pleated sq. ft. 8 Summary: The filter with the most surface area will maintain a lower pressure drop (less restriction) over time, since it has more surface area for much greater dust holding capacity. 2" Best Choice = FARR 30/30 or high capacity * Filter has not been tested under the MERV procedure. The noted rating is an estimate.
12 Different Filter Types Air Flow verses Pressure Drop Filter Size: 24X w.g. Amount of Surface Area 52.1 Rated Efficiency MERV 1" Poly Framed Filter sq. ft. *5 3-4* FGI 400 Series SC 1" Pleated sq. ft Camfil Aeropleat III 1" Pleated sq. ft Camfil Aeropleat IV 1" Pleated sq. ft * Camfil Farr 30/30 1" Pleated sq. ft Fiberbond FDL 1" Ring Panel sq. ft " Poly Framed Filter sq. ft * FGI 400 Series SC 2" Pleated sq. ft Camfil Aeropleat III 2" Pleated sq. ft Camfil Farr 30/30 2" Pleated sq. ft Fiberbond FDL 2 Ring Panel sq. ft Summary: The filter with the most surface area will maintain a lower pressure drop (less restriction) over time, since it has more surface area on which to load contaminant. * Filter has not been tested under the MERV procedure. The noted rating is an estimate.
13 FILTER HOLDING FASTENERS
14 FILTER HOLDING FASTENERS
15 Filter Holding Fastener
16 Filter Holding Fastener
17 Fan Powered Box retrofit
18 Fan Powered Box retrofit, Size: 24X20X2
19 Fan coil unit consists of a fan that blows room air over a coil of finned pipes that carry heated or chilled water. Some types have a single coil supplied with hot water; these can only heat the air. Others types have a single coil supplied with chilled water, these can only cool the air. Yet others have 2 coils and heat or cool the air. The electrical loading is small, consisting only of a fan and usually a controller that operates valves to control the flow of heated or chilled water. Almost always single phase. The chilled and/or heated water would be supplied by remote central plant, with appreciable energy use.
20 AIR FILTER SOLUTIONS INC. THANK YOU FOR THE OPPORTUNITY IN SPEAKING
22 Evaporative PreCooling for Air-Cooled Condensers
23 The Evaporative PreCooling Principle Increase Cooling Capacity Reduce Energy Usage
24 Small Packaged Unit Performance Data (12.5 Tons) CAPACITY INCREASE Increase in Tons 11% Decrease in KW 19% Increase in SHC 6%
25 CAPACITY INCREASE Mid-size Scroll Compressor Chiller Performance Data (50 Ton) Increase in Tons 11% Decrease in KW 18% Increase in EER 27%
26 Large Scroll Compressor Chiller Performance Data (100 Ton) CAPACITY INCREASE Increase in Tons 11% Decrease in KW 19% Increase in EER 27%
27 kwh ENERGY SAVINGS Unit Description: Location: Customer: 40 Ton Packaged Condensing Unit Cypress, TX (Houston Area) Large Telecom Company Summary of Results Cooling Degree Day (CDD) Without PreCooling With PreCooling CDD % Savings % % % % % % %
28 ENERGY SAVINGS Evaporative PreCoolers Installed
29 REDUCED MAINTENANCE Cleaner coils mean more efficient operation. A dirty condenser coil can increase compressor energy consumption by 30%. - Federal Emergency Management Program Fact Sheet If the coil is dirty. this raises your electricity cost for air conditioning and may shorten the life of the outdoor condensing unit. - Saturn Research Management
30 WATER CONSERVATION The National Renewable Energy Lab (NREL) reports: U.S. electricity production consumes over 20 gallons of water per KWH created. Other studies confirm this water usage, and state that depending upon the power plant type, the water usage can range from 10 gallons to 25 gallons of water consumed per KWH created. PreCooling systems use approximately 1.9 gallons of water for each KWH saved. This savings covers 90% of water usage cost while saving electricity Precooling systems annual water costs are measured in hundreds of dollars, while saving thousands of dollars annually in electricity costs. By reducing electricity demand and consumption Evaporative Cooling actually SAVES water on a global scale!
31 ADDITIONAL BENEFITS Reduces Energy Use Reduces Demand Charges Reduces Overall Maintenance Increases tonnage capability Improves the KW/Ton Ratio Reduces Head Pressure Increases system reliability Protects Coils from Debris and Damage Extends the life of HVAC equipment
32 XCEL ENERGY REBATES Direct Evaporative PreCoolers for Air-Cooled Condensers (DEPACC) The measure will focus on retrofits for existing commercial rooftop units 10 nominal tons or greater. Public Service will provide a prescriptive rebate of $100/nominal ton of cooling for the installation. The rebate will be capped at 60% of total project cost and will be consistent with the existing terms and conditions of the current Public Service Company prescriptive measure incentives and measure. DEPACC will contribute 2,788 net generator kw of demand savings and 2,465,098 kwh of electric savings. The forecasted spend amount for this new measure is $1,102,500.
34 HVAC Upgrades Not of age requiring replacement, but new enough to justify upgrading.
35 Control Panel Upgrade Adaptive Frequency Drives Renewal / Refresh Programs
36 Control Panel Upgrade
37 What is it? Comprehensive retrofit package for centrifugal chillers regardless of manufacturer Includes a complete enclosure with all of the Intelligent Devices necessary to control: Chiller operations Temperature and pressure sensors Wiring harnesses Display and a mounting swing arm
38 Control / Human Interface Upgrade Present CH UCP Classic Black UCP Single door pneumatic Double door pneumatic
39 Why? Upgrades controls to newest digital controls and operator platform Easy to use and output enhances the operators knowledge of chiller operations Improves reliability which will help achieve customer s financial goals by saving on operating cost and preventing expensive failures Features... Intuitive color display Chiller logging Chiller trending Fully digital controls Communication w/bas Adapts chiller to situation and creates alert. Decrease utility demand charges. Soft loading. Benefits... Easy access to information More data available Reports and graphs Similar panel to new production Increased reliability Improved temperature control Enhanced motor protection More BAS options
40 Screen shots - view of the chiller
41 Screen shots - view of the chiller at-a-glance
42 Screen shots - view of the evaporator data
43 Screen shots - view of the condenser data
44 Screen shots - view of the compressor data
45 Screen shots - view of the motor data
46 Adaptive Frequency Drives
47 What is it? Retrofit package to replace motor starter on centrifugal compressor water chillers. AFD is designed to maximize chiller efficiency and reduce power consumption by adapting the motor speed to the chiller s operating load Designed to interface with a variety of controls Suitable for CVHE and CVHF chillers Offered as unit mounted or remote mounted Using adaptive logic, the AFD meets the systems required load conditions and at the same time maintains maximum efficiency of the chiller By communicating with the control panel, the AFD maintains safe and uninterrupted chiller operation
48 Chiller With AFD Retrofit Can be unit or remote mounted.
49 Why? Does anyone have a chiller that runs 100% loaded, 24 hours a day, 365 days a year?
50 Features and Benefits - Energy Savings AFD Comparison Curves kw/ton % 30% 40% 50% 60% 70% 80% 90% 100% Percent Load Without AFD, Without Condenser Relief With AFD, With Condenser Relief
51 Applications Serves buildings with a variety of cooling needs Commercial offices Retail buildings Chillers with high run hours (over 1,000) at part lift Facilities where water temperature can be reduced by 10 degrees or more an AFD will result in higher savings Hotels Data processing facilities Arena and Sport Complexes Systems designed for peak operation (sporting event, game, etc.) 24-hour dehumidification for locker rooms, pools, etc. Manufacturing facilities
52 Applications Product Overview Misapplied chillers Oversized chillers (older chillers were sometimes oversized) Building that have changed owners and type of use Heat recovery or ice making that is no longer used Hospitals Hotels Soft start requirement, reduces startup inrush High utility rates Utility rebates available.
53 Renewal/Refresh Programs
54 What is it? Renewal / Refresh Webster s definition: re new: to become new or as new; to begin again. an investment that delivers a manufacturer s original commitment of reliability and performance that is backed by a long-term warranty.
55 For what Products Centrifugal Chillers Helical Rotary (screw) chillers (air cooled and water cooled) Large Package Rooftops Units (>20 tons) Vertical Self Contained Units. Building Automation Systems
56 What is Renewal / Refresh Service Program? Under Normal Conditions, Components Can Wear and Deteriorate Over Time... Gaskets - internal and external elastomer seals give up elasticity and harden with time. The rate of deterioration depends on time, temperature, and operating conditions. Bearings - individual unit-operating conditions can influence bearings performance. Certain site conditions can cause bearing damage and ultimately compressor failure. Slide Valve slide valve wear, common result is the loss of load and temperature control.
57 What is Renewal / Refresh Service Program? Technology improvements can lead to improved performance. Mechanical Upgrades can lead to improved efficiencies and reliabilities. Software Upgrades can also lead to improved efficiencies and reliabilities.
58 Why? Budget Constraints Saves Money vs. Compressor Failure or Unit Replacement - Budgeted Expense, Planned, Predictable, Not a Surprise Lowest Life Cycle Cost for Your Equipment Proactive - while compressor wear is not preventable, catastrophic compressor failure can be reduced Financial Constraints With a Major Failure or Complete Chiller Replacement Budget planning in advance Maintenance budget vs. capital expense
59 Why? Long term assurance... Additional two, three, five year parts and labor warranties available. Environmentally conscious - prevent refrigerant leaks Legal (and moral ) obligation to conserve the environment
60 Chillers, Package Equipment Remanufacture Compressor to original specifications Replaced and/or upgraded parts to current OEM specifications Install latest compressor upgrades Oil & refrigerant analysis Eddy current tube analysis Motor contactors, (compressor, fan) Auxiliary switches Wiring harnesses Proving switches Phases monitor Supply/Return fan motor bearings Condenser fan motors Fan hub seals Upgrade fan blades to quieter, more efficient Upgrade economizer actuators Replace economizer actuators linkage. Fan support brackets Door gaskets, latches, and screws Replace Insulation Clean/repair drain pans Out door pressure sensor tubing Clean dirty condenser and evaporator coils Clean dirty condenser and evaporator tubes Repair refrigerant leaks
61 Summarizing A Thorough Equipment Evaluation Restored Unit Compressor to the OEM s Current Specifications Replaced and/or upgraded parts to current OEM specifications A new serial number to reflect the changes Save money - 1/2 the cost of a compressor failure Scheduled downtime Budgeted expense Long term compressor assurance Standard two-year parts and labor compressor warranty Additional three-year parts and labor warranty with a service agreement Prevent refrigerant leaks conserve the environment
63 BAS R newal Advantages of planned upgrade Cost advantage of control system upgrade vs. control system replacement 2x to 4x less expensive to upgrade control system than to completely replace system Tracer R newal retrofit kit utilizes existing enclosures Utilizes other existing system components, including wiring No need for electrical contractor and associated costs 63
64 Building Automation Software upgrades uploaded Upgraded graphics Graphic data trending and reporting Standard report libraries Strategies to reduce energy usage Ventilation optimization procedures Static pressure optimization Chiller-Tower optimization Lighting Control Advanced alarm management
65 Why? 65 Keep building operating at high performance Keep control system operating properly Compensate for any changes Find areas of building systems improvement Avoid unplanned failures or obsolescence 2x to 4x less expensive to upgrade control system than to completely replace system
66 R newal Upgrade Program In conclusion Many reasons to upgrade Avoid obsolescence and risk Improve operational efficiencies Many advantages of upgrade Less cost than system replacement Easier on your budget Maximize system operation Protect investment into future 66
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