renewable energy systems for building professionals great lakes brewing company case study

Case Study

Great Lakes Brewing Company Cleveland, Ohio

HVAC and Domestic Hot Water System Renovation

Andy Culberson

Geisel Mechanical

Case Study HVAC and Domestic Hot Water System Renovation

• Established in 1988 by brothers Patrick and Daniel Conway, Great Lakes Brewing Company became the first microbrewery in the state of Ohio and today remains Ohio's most celebrated and award-winning brewer of lagers and ales.

The care that goes into the beer resonates from a commitment to the community and environment, otherwise known as the "Triple Bottom Line" - to engage in economic, social and environmental practices that achieve a sustainable, yet profitable, business. These include:

Reducing, reusing and recycling Changing natural resource use from "Take, Make, Waste" to "Take, Make, Remake" Implementing efficient energy practices Investing in the community through non-profit organizations Supporting sustainable urban renewal projects


• The Victorian building at 2516 Market Avenue that houses the Great Lakes Brewing Company Brewpub was established circa 1865 and became a popular watering hole for Cleveland's legal professionals and tradesmen. Its most famous patron was Eliot Ness, former leader of Chicago's "Untouchables" and the man credited with taking down Al Capone's gang.

As lifelong supporters of environmental causes, the Conway brothers have incorporated "zero waste initiatives" into day to day operations. "While we're strong proponents of operating a manufacturing enterprise that is environmentally friendly, we also realize that it has to make financial sense.


• The Brewpub, Gift Shop and Office area is actually three historic buildings merged: The Market Tavern, McClean's Feed & Seed Company and the Elton Building.

Above the Brewpub are two facilities known as the Market Room and the Rockefeller Room, which served as law offices for a young John D. Rockefeller before he got his start with Standard Oil.


Project Area Existing Conditions

• Restaurant has metered water usage of 1600 gallons per day

• (2) 40 year old 275,000 btu gas forced air furnaces

• Gas utility history from 2006

• (2) DX Cooling Coils with a 7.5 & 10 toncondenser on the roof

• Carrier iVUE Control System

Great Lakes Brewing Company is a principle-centered, environmentally respectful and socially conscious company committed to crafting fresh, flavorful, high-quality beer and food for the enjoyment of our customers.


Project Area Existing Conditions

• Outside air blocked off for energy savings

• Negative building air pressure from kitchen hood; no MUA

• 8 year old 100 gallon, 500,000 btu under fired hot water tank

• 2nd, 3rd, 4th floor of Elton Building required new HVAC as part of a totalbuilding remodeling

The brewery consists of six buildings, three of which originally served as horse stables and kegging facilities for the Schlather Brewing Company .


Methodology

• Full site survey, equipment inventory, energy analysis

• Load profiles developed for all areas

• Determine ventilation rates for kitchen

• Determine outdoor air requirements for occupants

• Review solar tax credit information

• Budget and review with owners

We aspire to maintain our status as the premier craft brewery in the Great Lakes region and are dedicated to uncompromising service, continuous improvement and innovative consumer education.


Prioritize projects based on need and budgets

- Flue gas entering the space from the negative building pressure

- 40 year old furnaces falling apart

- Elton Building needed new HVAC

- Kitchen hood needs make up air

- Code required ventilation air for the restaurant

- Hot water heater beyond its useful life

- Increased water use due to new dishwashing equipment

- 30% Federal Tax credits for solarGreat Lakes Brewing Company's distribution area now extends to Illinois, Indiana, Kentucky, Michigan, New York, Pennsylvania, West Virginia and Wisconsin.


Project Selection Criteria

• Take full advantage of federal tax credit

• Incorporate solar into entire project

• Interconnect all systems

• Connect to iVUE control system

• Use hot water boiler for backup to solar

• Use hot water fan coils for air side heating

• Use evacuated tube solar panels on the roof

• Use solar PV DX systems for

Elton Building heat pumpsThe three waves in the company logo not only reflect this Triple Bottom Line philosophy, they represent a concerted effort to the respectful use of beer's most valuable ingredient - water.


Mechanical Room Layout


Roof Section Solar Panel Layout


Solar Panel Layout


Typical Floor Mechanical


DX Heat Pump Layout


Product Selection

Lochinvar XL 500 Condensing and Modulating Gas Boiler

(2) Heat Transfer Products SSU119SB Solar hot Water Storage Tanks – 119 gallons

12- Heat Transfer Products HP-30SC Evacuated Tube Solar Panels


Product Selection

Caleffi 8600-047 BS Solar Controller

Grundfos Magna Variable Capacity Pumps

Carrier 40RM Fan Coil with DX cooling and hot water reheat


Heat Controller AHBV Variable Capacity DX/Hot Water Fan Coil

Product Selection

Lennox XPG 20 Solar Assisted Heat Pump


Product Selection

Carrier iVUE Control System


Carrier iVUE Control System

Product Selection


GLBC operates a beer delivery truck and a shuttle bus called "The Fatty Wagon" that runs on straight restaurant vegetable oil. Results show that engines running on straight vegetable oil produce 40% less soot than diesel and are 25% cleaner.


Proposed Phase Two – Brewery Solar


Pictures

High Temperature Insulation and Jacketing


Pictures

Piping and Control Board

Delta T Variable Speed Pump to Solar Panels

Bon Appetite


Tax Credits

Total Project Cost

Solar System $80,000

Hot Water Boiler System $41,000Hot Water DX Fan Coils $74,000

Total $195,000

Less Tax Credit of 30% $58,500

First Year Energy Savings $7200

Solar System - Tax Credits / Energy Savings = 2.98 year ROI


Questions?

Evacuated Tube Typical

renewable energy systems for building professionals great lakes brewing company case study

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