workshop d - thermal energy measurement - mec … gas – 8 meters ... magnetrol ta2. accurate steam...

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Workshop D

Best Practices for Thermal Energy Measurement …

The Starting Point for Energy Conservation

Savings

Tuesday, February 21, 2017 10:45 a.m. to Noon

Biographical Information

Brad Papa, Vice President of Sales and Service Chaltron Systems, Inc., 7757 Auburn Road #14, Concord, OH 44077

440-639-6400 [email protected] Brad started his instrumentation career with Chaltron Systems, Inc. in 2004 as a technical sales representative. Brad progressed at Chaltron Systems to Vice President of Sales and Service. In his 12+ years in the industry, Brad has commissioned over 500 flow meters with technologies ranging from Ultrasonic Transit Time Flow Meters, Thermal Dispersion Gas Flow Meters, and Vortex Shedding Flow Meters. Brad is a routine speaker at technical sessions sponsored by the OWEA and OAWWA where ongoing continuing education credits are provided, as well as providing presentations to engineering firms and end users about best practices for implementing instrumentation. Brad’s primary responsibilities include oversight of sales and field service, technical support, customer training, networking communications, troubleshooting equipment, and identifying best solutions for tough applications.

Eric Papa, Instrumentation Sales & Marketing Chaltron Systems, Inc., 7757 Auburn Road #14, Concord, OH 44077

[email protected] Eric started his industrial marketing career with Parker Hannifin Corporation in 2005 as an Audio/Video Engineer at the company's global headquarters. Eric progressed quickly within the organization and in 2007 became a multimedia marketing consultant to the company, traveling internationally to develop and deploy new technology strategies for divisions in the Hydraulics, Engineered Materials, Instrumentation, Filtration and Aerospace Groups. In his 11+ years in the industry, Eric has overseen more than 200 engineering marketing projects for multiple companies. Eric joined Chaltron Systems in 2015, and has since used his experience to better help customers understand flow metering technologies and other associated instrumentation. His sales focus is on the Toledo, Dayton, and surrounding areas. Eric is a routine speaker at engineering firms and develops any needed marketing materials for the company directly in-house at Chaltron. Eric’s primary responsibilities include sales, new marketing strategies, promotions, streamlining of processes, technical support, and identifying best solutions for tough applications

Best Practices for Thermal Energy MeasurementThe Starting Point for Energy Conservation Savings.

Eric PapaSales and MarketingChaltron Systems, Inc.

Eric PapaSales and MarketingChaltron Systems, Inc.

• 12+ Years of experience• Industrial Sector

- Providing Measurement instrumentation and data collection since 1984

- State of the art solutions for the Industrial, Municipal and Commercial Energy Markets

- Committed to building lasting relationships with our customers

The focus of this presentation is to provide energy, water, and facility managers with a framework to achieve accurate, reliable, maintenance free metering of fluids.

• Water• Steam• Natural Gas• Compressed Air• Hot/Chilled Water• BTU• Condensate Return

Optimize existing asset performance resulting in continuous improvement and long term savings.

• Industrial Plants• Universities/Colleges• Medical Centers• Commercial Buildings• Energy Providers

Where do I start?

What do I need to measure?

What type of equipment is used?

When should I start?

Why should I meter / Sub meter?

How much does this cost?

3 Key Learning Objectives of this Presentation

1. Applications & Terminology2. Performance3. Proper Equipment Selection

Understand what utilities need to be measured, and the proper terminologyassociated with the application.

1.

Understand metering errors dueto inaccuracy and unreliable performanceresult in major cost savings or losses.

2.

Introduce advanced metering technologies and how best to apply them.

3.

Case StudiesReal World Case Studies and Success Stories

Steve BarlowEnergy Manager Cleveland VA Medical Center

Erika WeliczkoEnergy Manager Case Western Reserve University

David MusserDirector of Energy OperationsThe University of Akron

1.Applications & Terminology

Brad PapaVP Sales and ServiceChaltron Systems, Inc.• 13+ Years of experience• Industrial Sector• Over 500 flow meters commissioned

IndustrialPlants

Universities

MedicalCenters

CommercialBuildings

EnergySuppliers

Steam (Btu)

Chilled/HotWater (Btu)

Water (GPM)

Natural Gas (Scfh)

Compressed Air (Scfh)

“How close does the measurementand the actual value agree.”

Accuracy

% of span - GOOD% of rate - BEST

AccuracyExample % of span - Meter span = 0 – 100 GPMAccuracy 1% of span = 1 GPM is 1% of value@10 GPM accuracy = 10% of value

Example % of rate - Meter span = 0 – 100 GPMAccuracy 1% of rate = 1 GPM @100 GPM@10 GPM accuracy = .1 GPM

Accuracy – Percent of Span

Accuracy – Percent of Rate

“How close does the measurementgive identical indications when applicationsare repeated.”

Repeatability

% of reading

“How close does the measurementalign with the ideal output.”

Linearity

% of reading

“Ratio of maximum value measuredto the minimum value that can bemeasured.”

Turndown

Example: 100 GPM Maximum5 GPM Minimum

Turndown = 20:1

“Does the meter continue to performaccurately for the next 25+ years.”

Reliability

“Does the meter or any auxiliarycomponents require recalibrations andrepairs.”

Maintenance Free

“Can the meter calculate mass flow,BTU’s, and/or perform pressure andtemperature compensation in (1) unit,or are multiple transmitters and flowcomputers required.”

Single Processor

Erika WeliczkoEnergy Manager Case Western Reserve University

“What I like most about beingan energy manager is that there are plenty of opportunities forimprovement all over.”

- Erika Weliczko

Current Metering Footprint

• Electric meters: 260+

• Chilled Water meters: 12

• Steam meters: 16

• Steam Condensate meters: 8

Thoughts on Progression

“Energy management willcontinue to grow over the next10 years as providing the usageinformation to more users and occupants will continue to becomemore and more important.”

- Erika Weliczko

RecommendationsFor New Users

• The energy field is so large it is very importantto define targets

• Question the total cost of ownership to achievea long term impact and push for accountabilitybased on measurable information

Thank you!

- Erika Weliczko

2.Performance

“How important is meter accuracy?”

Meter Accuracy

• Chilled Water 12” Line• Existing mechanical meter reading: 152 GPM• Advanced technology meter reading: 409 GPM• Error of 257 GPM

Large University in Ohio

• @ $0.30/ton-hour• Loss of revenue = $777.00/day


$23,310.00/monthMeter accuracy is very important!

Prone to build up and breakdown over time.

Insertion Turbine

Not a question ifthis will fail, but when it will fail.

How important is temperature accuracy?

Temperature Accuracy

Poor Quality RTD

1000 Ohm matched RTD’sare accurate to +/- .03 F

• Chilled Water 12” Line• Flow rate: 500 GPM• 1 Degree F error• Loss of revenue of $125.00/Day


$3,750.00/monthTemperature accuracy is very important!

How important is flow turndown?

Flow Turndown

• Domestic Water 12” Line• City utility water supply to University• Common use: Blending, Optional use: Total Supply• Common use = 100 GPM (.30 ft/sec)• Below minimum capability of existing magnetic

flow meter• Installation of ultrasonic meter measures as

low as .01 ft/sec (3.50 GPM)


• Loss of revenue $600.00/Day


$18,000.00/monthTurndown allowing for measurement of extremelylow flow rates is very important!

Steve BarlowEnergy Manager Cleveland VAMC

Steve BarlowEnergy Manager Cleveland VAMC

• Energy Manager since 2008• 35+ Years of engineering experience• Registered PE (Ohio) and AEE Certified Energy Manager

“What I like most about beingan energy manager is the ability tofocus on initiatives I feel are importantand continually learn new technologieswhile keeping abreast of industrydevelopments.”

- Steve Barlow

My Message

• If you can’t measure and quantify it, you can’tmanage it.

• Metering doesn’t cost; it saves by helping you“see” things you otherwise would not.

• Metering must be effective and consistent.

SBS System

Current Metering FootprintElectrical – 110 meters • Utility main feeds, substation main busses,

& substation feeder circuitsNatural Gas – 8 meters• Utility main feed, boiler feed, &

one/boiler from boiler controlsDomestic Water – 7 meters• Utility main feeds, boiler & chiller make-up water

and DHW supply, return and make-upSteam – 11 meters• Each (4) boiler, (7) main distribution feedsChiller Plant and AHUs – 43 meters• CHW plant supply-return, cooling towers, AHU(BTU) 31 CHW, 2 AHU HW

& (7) chillers from chiller controls

Immediate Benefits

• Thermal Dispersion flow meter on Natural Gasresulted in a $114,000+ credit – (New meterinstalled by utility company had an RF interferenceproblem, overbilling by 2x)

Immediate Benefits

• Ultrasonic meter was reading error onHot Water preheat coils resulting in repeatedfreeze stat trips on 2 AHUs

• Units were not getting proper water flow

• Bled coils and resolved the problem

• Meter continues to read properly


“I see Smart Building Technologygrowing and growing – the internetof things and Big Data will becomemore and more of a necessity foranyone involved in facility managementand energy conservation.”

- Steve Barlow

Closing Thoughts

• Tremendous eye opening experience on thecomplexities of metering

• Tremendous value of metering when done properly

• Large emphasis on proper meter sizing – very critical

• Critical importance of identifying the general rangeof actual flow rates – vitally important for sizing

Closing Thoughts

Insertion Vortex Meter Remote Electronics

Previous DP: 2lb/hrActual Vortex: 1,249lb/hr

Thank you!

- Steve Barlow

3.Proper Equipment Selection

Accurate gas flow measurementrequires large turndown and themeasurement of the fluid’s temperature and pressure in addition to flow to compensate for density changes.

Thermal Dispersion technology measures ona mass basis eliminating the need for densitycompensation, and has a turndown of 100:1.

Natural Gas/Compressed Air

Insertion or in-line meters are available

Magnetrol TA2

Accurate steam flow energy content measurement requires large turndown and the measurement of the fluid’s temperature and pressure in addition to mass flow.

New Vortex metering technology providesinternal pressure and temperature compensationalong with an Enthalpy (BTU/lb) lookup table tooutput in BTU’s/hour.

Steam

Insertion or in-line meters are available

VorTek M22/M23

Single processortechnology instead of a combination of multiple transmitters and a flow computer.

Accurate technology with a large turndownratio is critical for water flow measurements.

Temperatures can vary from 40F to 400F andbeyond. High accuracy temperature measurementsare required for BTU metering.

A single processor BTU meter is desired.

Hot Water/Chilled WaterBTU Metering, Domestic Water

Metering of steam flow can be a challengedue to large seasonal turndown requirements.Measuring Condensate Return can solve thisproblem.

Fast processing with an internal temperaturemeasurement is required for mass flow.

Condensate Return

Single processortechnology instead of a combination of multiple transmitters and a flow computer.

Flexim F704 Ultrasonic

• Rubber coupling pads (no more grease)• Matched, calibrated, temperature compensated

transducers with NIST traceability• Rugged construction, including mounting

assemblies and SS armored cable• Fast processing• High Accuracy RTD’s• Wave Injector for (-300F to +1000F) applications

Advanced UltrasonicTechnology


• Energy Management since 1995• 30+ Years of engineering experience

“ The most rewarding parts of being an energy manager are savingyour company significant moneyand knowing that by doings so,you’re protecting the environmenteither directly through modern technologiesor indirectly through reduced consumption.“

- David Musser

Starting Point

• Started in 2004 to meter HTHW system

• Steam was purchased from Akron Thermal

• Chose Flexim for its high temperature and lowflow measuring capabilities

Metering Goal

• Measure 400F campus heating water supply

• Install meters but avoid shutdowns on campus

• Also meter Chilled Water and Domestic Water

Wave Injector

Unique Hi Temperature Non-Intrusive External Measurement Solution

Current Metering Footprint

• 40+ HTHW, Hot Water, Chilled Water, Domestic Water

• 6 Natural Gas Meters

Immediate Benefits

• Simple installation with no serviceinterruptions

• Accurate and reliable flow measurementof 400F water in 20 locations – Foil coupling pad

• Quantification of under billing – the Flexim meterwas capable of reading lower flows where the suppliersmeter would drop out

• Little to no maintenance required

Immediate Benefits

• Flexim meter used for billing other entitieson campus accurately

• Regardless of flow, meter maintains accuracy


“The subject of utility usage for any business is a highly important part of the company’s budget.For the University of Akron, it isa matter of survival…”


“..Utility usage measurement isthe first step in controlling thatportion of the budget. Metering willcontinue to become more importantwith each passing year as budgetsbecome scrutinized more closely.”

- David Musser

Thank you!

- David Musser

workshop d - thermal energy measurement - mec … gas – 8 meters ... magnetrol ta2. accurate steam...

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