Benefits of renewing large heating systems and integration with process heat recovery

1. Benefits of renewing large heating systems and integration with process heat recovery Comparison of old & new systems. How are the savings calculated? What are the results? How was heat recovery incorporated?

2. David Parry • Background in Architecture • Member of CIBSE • Energy Manager for IBSA • Printing HQ in UK for Watchtower • Worldwide - Greatest circulation magazine – 45 million/month • Website – 900,000+ visits per Day!

3. IBSA House Factory built 1987-88 Boiler Room IBSA House – Office built 1992-93

4. Profile of Projects • IBSA House – headquarters building in north London • Printery and five storey office complex – total area = 19,000 m² • IBSA House – installation of Buderus boilers • IBSA House – LTB Heat Recovery System

5. Original Boilers • 18 x 100 kW gas fired atmospheric boilers installed in 1987 • 150 mm Primary Loop within Plant Room powered by three circulators • Zone pumps circulate to secondary circuits • Shunt pumps added to boilers to improve flow

6. Original Boiler Room

7. Three primary pumps

8. Zone Pumps Header

9. Problems encountered • Aging units, spare parts increasingly difficult to source. • Lower cast iron casings crackingand leaking • Several boilers had to be isolated • Maintenance labour costs escalating • Diminishing heat output causing complaints on upper floors of office

10. Proposed Improvements • New gas pressure jet high efficiency boilers • 6 x 350 kW Buderus G515 selected • Each boiler has own shunt pump • Connected to vertical hydraulic low loss header • No primary loop or pumps • Secondary circuits & Grundfos Magna pumps off zone header • Weather compensation added where needed • High quality insulation applied • Integrated into BMS (Trend Controls)

11. “If you cannot measure it, you cannot manage it.” Installed pre-project Sub Meters are vital

12. IBSA Boilers – savings generators!

13. How are savings worked out? • Gas sub-meters read monthly • Data entered in CIBSE Metering Proforma – tracks monthly consumption, gas, water, electric • In Excel: Scatter graph – months consumption v Degree Days (degrees below 15.5°C per day) • Graph generates formula, used to predict consumption before changes made • Predicted minus actual = savings

14. Base Year Gas Meter Consumption X axis Y axis

15. Scatter Graph

21. BOILER ROOM ELECTRICAL CONSUMPTION

22. Additional Benefits - CCA Climate Change Agreement Watchtower under umbrella of BPIF – British Printing Industry Federation £13,193 Climate Change Levy – Tax Back

24. Summary of benefits • Reliable heating system • Reduced maintenance / servicing costs • Annual savings: • Gas savings – 1,250,000+ kWh • Electricity savings – 55,000+ kWh • Financial savings - £45,000+ and increasing • Carbon footprint reduction by 240 tonne CO2 • Qualification for CCL reduction - £17,800+ • BREEAM Building Rating – Very Good • Relocate two boilers in another building

25. MAN Roland printing press 94,000

26. Process Heat Recovery Promotion Video Shown entire staff (600) and All new members during Induction Week

28. Luft und ThermoTechnik Bayreuth Flue Heat Recovery Unit by Econotherm LTB HT Fan

29. Heat Recovery Unit on LTB

31. Measuring the Savings • Year 2013 -full year’s data • Temperature sensors in the flow and return • Pump flow rates measured during commissioning • Formula: kW = 4·18 x Q x Dt • Virtual sensors recording kilowatt energy savings every 30 minutes • Values uploaded into database. (Plexus/Kaldien Energy Suite) • Data measured in two locations: • (1) by heat recovery unit • (2) at measuring station 90 m away in the boiler room • Average used to determine the recuperation of energy

32. 140 kW

33. In summer: recovered heat provides for DHWS & spray booth

34. Measured benefits • Annual results – 2013 • Minimum recovery = 150,606 kW • Maximum recovery = 206,139 kW • Mean recovery = 178,372 kW • x boiler efficiency factor 86% = 207,407 kW • Gas saved @ 2.96 p/kW = £6,131 • CCL @ 0.182 p/kW = £377 • Cost to power fan and pumps = - £450 • Total saving = £6,058 • Payback period = 8 years

35. Lessons • Less heat recovered than expected – 140 kW/hour, not 200 kW/hour • Change in production pattern – shorter runs • Need for process to be in control caps input • Adjusted to pre-warm during standby

36. Benefits • Energy recuperated from process • Good energy conservation news for visitors • 20,000 on tour per year • Financial savings • Heat recovery viewed by energy assessor as renewable source • Contributes to DEC - Band B • BREEAM - 67% -Very Good

37. Keep conserving Energy