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2016DTE Energy EfficiencyProgram for Business

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• 8:30 – 8:35 Introduction• 8:35 – 9:10 DJ Conley• 9:10 – 9:40 Performance Engineering Group• 9:40 – 10:00 Break/Networking• 10:00 – 10:35 Greffen Systems• 10:35 – 11:05 RL Deppmann• 11:05 – 11:25 DTE Energy Efficiency Program for Business

• 11:25 – 11:30 Closing Remarks• 11:30 Lunch and Networking

Agenda

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Technical Presentations

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DJ Conley

DTE - BOILER SYSTEMS

MARCH 30, 2016

ERIC CAMERON

ECONOMIZER INSTALLATION

OLD STYLE ECONOMIZERDESIGN 0.50” WC BACK PRESSURE AND BOILER SIZE

10 DEG. F ON FEED WATER RISE AND 100 DEG. F OUT OF FLUE GAS

OLD STYLE ECONOMIZER CARBON STEEL TUBE OR PIPE

PRONE TO O2 PITTING

NEW STYLE ECONOMIZER FOR 0.25” BACK PRESSURE RECOVERS HEAT UP TO A PRESSURE POINT OF 0.25”

THEN DAMPER OPENS TO KEEP PRESSURE IN RANGE FOR FGR APPLICATIONCAN BE MADE WITH DUPLEX STEEL

SIZED FOR FULL BOILER FLUE GAS FLOW RATE AT 0.25” BACK PRESSURESIZED TO RECOVER AS MUCH HEAT AS POSSIBLE DOWN TO DEW / CONDENSING POINT20 DEG. F OR MORE ON FEED WATER AND UP TO 200 DEG. F OUT OF STACK FLUE GAS

REPLACEABLE DUPLEX TUBES.

Two Stage Condensing Economizer Applications

– 1st Stage• Preheat Boiler Feedwater• On/Off Feedwater Control• Make-Up Water / Process Water

Heating• Hot Water Return

– 2nd Stage • Any Cool Liquid Stream (50 - 120 F)

– Make-Up Water – Process Water– Wash Water– Hot Water Preheating

Two Stage Condensing Economizer– 1st Stage

• Standard (Non Condensing) Economizer– 2nd Stage

• Condensing Economizer– 100 – 2200 Bhp Boiler applications– Condense on Natural Gas Only– Internal bypass for W.C. back pressure

control– All stainless construction– Hinged access door– Light weight Alfuse finned tube– ASME construction (150/300 PSIG

Design)

Two Stage Condensing Economizer Piping Diagram

ON DEMAND ECONOMIZER

PARALLEL POSITION COMBUSTION CONTROL

PARALLEL POSITION COMBUSTION CONTROL WITH VSD

PARALLEL POSITION COMBUSTION CONTROL WITH VSD AND O2 TRIM

FULLY METERED COMBUSTION CONTROL

PRELIMINARY PROJECT / PAYBACK / ECONOMIZERI used 1000 boiler horse power to keep it simple to convert to other boiler sizes. 1000 hp steam boiler = 34,500 pph ( Pounds Per Hour) Gas input is 41,840 SCFH / 41,840,000 BTU Input Natural gas cost is about $ 0.50 for 1000 SCF or 100,000 BTU The 1000 hp boiler producing 34,500 pph burns $ 209.20 an hour of gas. $ 5,020.80 a day $ 1,832,592.00 a year. Possible savings with an Economizer of 3% = $ 54,969.00 a year

BOILER STEAM FLOW: 35000

FUEL COST ($/THERM) $0.50

LOAD CONDITIONS: 100%

UNIT DUTY (BTH/HR) 1,004,000

BOILER EFFICIENCY: 80.00%

FUEL SAVED(BTU/HR): 1,255,000

SAVINGS PER HOUR: $6.28

HOURS OF OPERATION: 8760

SAVINGS PER YEAR: $54,969.00

A $ 165,000.00 project would have a 3 year payback. When gas cost go back up to $ 1.00 a $ 330,000.00 project would have a 3 year payback.

PRELIMINARY PROJECT / PAYBACK COMBUSTION CONTROL

Possible savings with Fully Metered Combustion Controls & O2 Trim of 1.8% = $ 32,987.00 a year BOILER RATING 35 KPPH

FUEL COST $5.00 /1000 FT3

NATURAL GAS FUEL

COMBUSTION FAN MOTOR 30HP

O2 MEASUREMENT WET

BOILER FIRING RATE 100%

STACK O2 EXISTING 4.5% O2 WET

STACK TEMPERATURE 550 F

PROJECTED STACK O2 WITH TRIM 2.5% O2 WET

PROJECTED STACK TEMPERATURE 537 F

TOTAL BTU SAVINGS 6,628 (MMBTU/YR)

ANNUAL FUEL COST $ 1,674,073.00

PROJECTED COST $ 1,640,932.00

TOTAL SAVINGS A YEAR $ 33,141.00

MAYBE TIME FOR A NEW BURNER

OLDER 250 HP BOILER WITH 15 HP BLOWER MOTOR

OLDER 250 HP BOILER WITH 7.5 HP FGR MOTOR

REPLACED BOTH 15 HP BLOWER MOTOR AND 7.5 HP FGR MOTOR WITH NEW STYLE BURNER WITH 5 HP MOTOR

ADDED PARALLEL POSITION COMBUSTION CONTROL WITH VSD AND O2 TRIM

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Performance Engineering Group

What really matters when it comes to boiler system efficiency!

2015 ML Baseball Regular Season Final Standings

Seed Millions/Win Seed Millions/Win

1

2

3

4

5

3

5

1

4

2

1.20

1.41

1.69

2.84

0.94

1.22

1.33

1.31

1.02

3.75

?? ??

Can’t Afford to get in the Game?• Who has unlimited resources for new equipment?• What is your expected ROI to fund a project?

• The capital you don’t spend may exceed your energy savings

• Happy Customers / Tenants /Fans

Primary Goal of Heating System

• Low Operating Cost (Total)

“Medieval” Thinking

“Medieval” Boiler System Metrics

• Primary Variable Flow

• Turn Down Rate

• Combustion / Thermal Efficiency

• Primary Secondary Pumping

• Direct Flow

The Current Design Prescription

• Condensing Boilers

• High Burner Turn Down

• Variable Speed Pumping

• Buffer Tank (?)

Not for those with a budget….

Game Changing Metrics that Really Matter

• Hours Per Cycle (HPC)• Peak Average Load (PAL)

• Optimal System Flow (OSF)

“Adapt or Die”

Hydronics 101

Gil Carlson ASHRAE Industry Pioneer / Bell &

Gossett

Hydronic Systems – Analysis and Evaluation Part 1 – 1968 ASHRAE Journal – G.F. Carlson

• Least accurate variable is building heat load

• +/- 10% would be a “good” load estimate

• Flow variation on heating components will deliver 90%output with 50% of the design flow @180⁰F

• Inadequate heat flow is best compensated for by increasedsupply water temperature

TURBULENTFlow Range

Impact of Managed ∆T

Typical System ∆T 3 to 5°F Managed System ∆T 15 to 25°F changes Efficiency 2 to 5%

Cycles (Yo-Yoing)

Hours 11,021Hours 27,801Cycles 74,957= 0.15Cycles 399,289= 0.07

What Causes Cycles

• Improper Control• Too Much Boiler

• Too Much Flow

Or…All of the Above

Finding Peak Average Load (PAL)Steps

– 2 peak months with actual reads

378+342 720

The Math

Feb = 378

Mar = 342

7202

=36036024

=1515

* 1.3 19.5 CCF Per Hour

Your Gas Bill

• Add them together / divide by 2 months / 24 hrs in a day• Multiply by 1.3• Result is approximate Peak Average Load (PAL)

Optimal System Flow (OSF)

19.5 CCF/hr *100,000 BTU/CCF1,950,000 *.90%eff = 1,755,000

1,755,000 500 X 20⁰F ∆T

= 176 GPM

Optimal System Flow

Maintain TURBULENT Flow

Rebate Double Play – Gas & Electric

– Larger payouts

• Multi-measure bonus potential

• Improves ROI

Optimized System Performance (OSP)

• Least costly option, typically < 50k• Control additions and modifications

– Reduce over response to heat load– Align boiler firing rate with PAL

• De-rate boiler(s) or replace burner(s) if ≥ PAL– Select best appliance to operate if multiple boiler sizes

• Flow– Modify flow rate to match OSF– Maintain design Loop ∆T across full pump range– Modify pumping (impeller trim/motor speed/VFD)– Maintain TURBULENT Flow at all times

Hybridize

• 30% to 50% of total modernization cost– Systems with useful life left– Changing what is controlled

• Add Pieces– System control to optimize devices– Pump/modifications/replacement– Add High Efficiency Heating Appliance

• Sized ≤ PAL

Modernization

• Replace Systems past end of useful life• Reevaluate/revise Everything

– Demand Profile– Terminal Devices– Delivery Strategies– Control

Top 10 Plays

Number 10Lakeview High School

Prior– 16,000 MBH Input– 2,400 GPM– 39 Pump HP – Hours per Cycle = 0.19

Post– 16,000 MBH Input– 350 GPM– 3.5 Pump HP– Hours per Cycle = 2.8

Optimization

Savings IncentivesGas Electric Gas Electric9k 8k 20k 7k

Number 9Lakeview Middle School

Prior– 18,000 MBH Input– 600 GPM– 14 Pump HP – Hours per Cycle = 2.00

Post– 18,000 MBH Input– 300 GPM– 3.5 Pump HP– Hours per Cycle = 4.0

Optimization

Savings IncentivesGas Electric Gas Electric20k 3k 20k 3k

Number 8Frost Middle School

Prior– 16,560 MBH Input– 600 GPM– 10 Pump HP – Hours per Cycle= 0.23

Post– 16,560 MBH Input– 300 GPM– 3 Pump HP– Hours per Cycle = 4.0

Optimization

Savings IncentivesGas Electric Gas Electric2k 3k 13k 2k

Number 7Rochester High School

Prior– 24,000 MBH Input– 1,968 GPM– 60 Pump HP – Hours per Cycle = 0.75

Post– 16,000 MBH Input– 570 GPM– 15 Pump Hp– Hours per Cycle = 3.0

Optimization

Savings IncentivesGas Electric Gas Electric30k - 54k -

Number 6Tawas Hospital

Prior– 12,000 MBH Input– Hours per Cycle = 2.0

Post– 8,000 MBH Input– Hours per Cycle = 24.0

– Left original boilers as oil fired emergency backup

– New LP storage/delivery system will eliminate old boiler

Hybridized

Number 5Calhoun County Justice Center

Prior– 18,000 MBH Input– 530 GPM– 30 Pump HP – Hours per Cycle = 0.16

Post– 16,500 MBH Input– 372 GPM– 8 pump HP– Hours per Cycle = 24.0

Hybridized

Savings IncentivesGas Electric Gas Electric31k - 5k -

Number 4Warren Woods Tower High School

Prior– 17,000 MBH Input– 1,200 GPM– 40 Pump HP – Hours per Cycle = 0.25

Post– 20,500 MBH Input– 770 GPM– Hours per Cycle = 6.0

Hybridized

Savings IncentivesGas Electric Gas Electric25k - 9k -

Number 3Brookside Greenhouses

Prior– 21,000 MBH Input– Steam– Hours per Cycle = 0.25

Post– 6,000 MBH Input– 3 Pump HP w/VFD– Hours per Cycle = 8.0

Modernized

Savings IncentivesGas Electric Gas Electric21k - 104k 2k

Number 2Kirk in the Hills

Prior– 21,000 MBH Input– Steam– Hours per Cycle = 0.20

Post– 5,500 MBH Input– Hours per Cycle = 6.0

Modernized

Savings IncentivesGas Electric Gas Electric28k - 45k -

Number 1Detroit County Day- Upper School

Prior– 13,000 MBH Input– 900 GPM– 20 PUMP HP– Hours per Cycle = 0.15Post– 4,410 MBH Input– 250 GPM– 1.5 Pump HP– Hours per Cycle = 24.0

Modernized

Savings IncentivesGas Electric Gas Electric53k 12k 31k -

Hamilton Engineering

• Livonia, MI Manufacturer– 95% Materials from MI– 100% of Labor from MI– 316L Stainless steel boilers– Up to 100 HP

• Pre-piped packages – Faster Installation– Less labor and Time– Less chance for error

A DTE Rebate Triple Play!!

In Summary To Achieve

A Perfect Game

Focus on

– Hours Per Cycle (HPC)

– Peak Average Load (PAL)

– Optimal System Flow (OSF)

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Greffen Systems

Green Boilers:Energy and Carbon Savings

March 30, 2016

GREFFEN (Green Efficient Energy) Systems

• Founded March 2008

• We focus on Public and Private sector organizations

• Greffen is a next tier solutions vendor

• Our products work with client’s existing heating and BMS systems– The M2G is a microprocessor technology which installs in about 3 hours– Commercial boiler applications that use gas and/or oil to heat buildings

• Few boiler energy saving solutions are available in the marketplace

U.S. Customers

• Atria West – Los Angeles• Baylor Medical Center• Bell Helicopter• Berry Center• Bronner’s• Brooks City Base• Cabrini High School• Carolinas Health Care• College of Charleston• Cymer• Cypress Fairbanks Schools• Donaldson Corporation

• Dow Chemical• Elon University• Electronic Arts• Ford Motor Company (Best Practices)• Fort Bragg• Fort Jackson• Fulton County Jail• General Motors (Best Practices)• Guilford Schools• Hewlett Packard• Internal Revenue Service• Iron Mountain

• Jackson Correctional Facility• JPMorgan Chase• L3 Communications• Lapeer Correctional Facility• Lara Academy• Life Technologies• Lincoln Harris• Lockheed Martin• Loyola University• Mancelona Schools• MacDill Air Force Base• Marist Schools

• Mecklenburg County• Michigan State University• Middle Georgia State University• Monsanto• Motorola• Mound Road Correctional Facility• New Brookside Apartments• Oakridge Apartments• Orchard Lake Saint Mary• Oracle• Palm Terrace – Orange County• Pilgrim Manor Nursing Home

U.S. Customers

U.S. Customers

• Pfizer• Reid House• Richland County Schools• Selfridge Air National Guard Base• South Carolina Dept. of Corrections• Sovereign Partners• State Of Tennessee• State Street Bank• State University of New York• Stratton Air National Guard Base• Sysco Foods

• Union Bank• University of Georgia• University of North Carolina Charlotte• University of North Texas• University of South Carolina• University of Texas Dallas• Vanguard University• Verizon• Waterford Public Schools• Wells Fargo• Yahoo!

M2G Pilot Results (Average = 15.4%)Customer Name Location Energy Savings

Baylor Medical Center Dallas, TX 14.0%Bell Helicopter Fort Worth, TX 16.9%Brooks City Base San Antonio, TX 11.0%Carolinas HealthCare System Mt. Holly, NC 27.9%Chicago Public Schools Chicago, IL 17.0%College of Charleston Charleston, SC 11.5%Cypress Fairbanks Schools Cypress, TX 21.0%Donaldson Corporation Bloomington, MN 20.0%Ford Motor Company Dearborn, MI 15.2%Hertz Logan Boston, MA 10.0%Hewlett Packard Boise, ID 14.0%Internal Revenue Service Atlanta, GA 18.7%L3 Communications Greenville, TX 7.3%Life Technologies Eugene, OR 13.0%Lockheed Martin Owego, NY 18.0%Loyola University Chicago, IL 10.0%Marist School Atlanta, GA 25.5%New Brookside Apartments Alexandria, VA 14.9%Nissan Aurora, IL 14.7%Oracle San Jose, CA 13.1%Pfizer San Diego, CA 18.0%State Street Bank Boston, MA 9.3%Sysco Foods Canton, MI 17.0%University of North Texas Denton, TX 14.3%University of South Carolina Columbia, SC 13.1%University of Texas at Dallas Dallas, TX 14.4%Yahoo! Sunnyvale, CA 15.6%

Utility Incentives• DTE Energy and Consumers Energy

– Prescriptive measure

– Up to 50% of the price of the M2G

• Laclede Gas

• Missouri Gas

• Nicor

• National Grid

• Vectren

What is the M2G Technology?

M2G Technology …• Microprocessor based technology • Reduces energy consumption by minimizing boiler dry-cycling• Match boiler operation with true building demand

ProblemWhat is dry cycling?

Boiler firing due to standing losses rather than building demand

• Boilers are oversized by design

• Maintain setpoint regardless of building demand

• Heat losses cause unnecessary cycling, “dry-cycling”

• The boiler fires over and over, even though there is no demand

M2G response to loading demand(boiler return water temperatures - by minute)

BMS and M2G will fire the

boiler here at the set point

Time (min)

ReturnTemp (°F)

0 165

1 165

2 165

3 163

4 160

5 158

6 156

7 156

Heavy Load

Light Load – Standing loss or “false” call

BMS sends “Call for Heat”

M2G holds off boiler

M2G might let boiler fire here at

same set point, but most likely hold off

boiler for even longer

Time (min)

ReturnTemp (°F)

0 165

1 163

2 163

3 162

4 162

5 161

6 161

7 160

8 160

9 160

10 160

11 158

12 156

13 154

M2G Technology …

SafeguardsThe M2G will allow the boiler to fire if:

• The boiler has been held off by the M2G by more than 15 minutes• The supply temperature drops more than 14.4°F• The return temperature drops more than 5.4°F• A real call for heat is detected • The M2G collects data every 10 seconds

Additional Safeguards• The M2G fails closed to insure boiler operations are not affected• Opto-isolators insure circuits are only monitored and not charged

M2G Technology …

Installation• Compatible with existing controls and operations

– Building Management Systems (BMS)– Outdoor Temperature Reset– Lead/Lag Controls

• Does NOT require any breaking of water lines• Minimal installation time (~3 Hours) • No maintenance required – “Set and Forget”• M2G doesn’t turn boiler on• M2G doesn’t turn boiler off• Provides intelligent delay

Aquastat or BMS

Burner Control

Boiler

Laboratory Verification

• Gas Technology Institute – Chicago, Illinois

Gas Technology InstituteTest Setup• Designed and built a model to simulate a building’s heating and cooling

loads• Winter thermal loads from a Chicago Public School were used in the

simulation• The thermal load profiles were attained from the Department of Energy

for use with EnergyPlus

Gas Technology InstituteResults• The initial laboratory testing

was positive and the results are being forwarded to the member utilities

• GTI wants to expand to field testing of the M2G

August 30, 2013

“Frank:

As usual the summer went by very quickly, I hope you are both doing well. I wanted to touch base on our recently completed and future plans for M2G-related activities:

Lab testing – As you know, we finished up lab testing earlier this year comparing youM2G to a competing product. Our results are currently under review by our utility sponsors and overall they are very pleased with M2G. We intend to publish these complete lab results to ASHRAE in January (without naming manufacturers) using the attached draft. Bottom line, we found that the M2G had 10% and 17% reductions in gas use for a simulated year in a school and hotel respectively, you may freely quote these results and being in a forthcoming published paper.

Overall the utilities have been pleased with the results, part of this field effort is supported by Nicor Gas who is interested in better understanding the potential savings of the M2G.”

Thanks, Paul Glanville, P.E.Principal Engineer Building Energy EfficiencyGas Technology Institute

• Year-over-Year Study performed by the U.S. Dept. of Energy

• Building Technologies Program

• Year-over-Year study with documented savings of 14%

• Named the new technology ALM (Advanced Load Monitoring)

Pilot Methodology

• Data loggers and Timers were install along with the M2G • The data loggers are placed on the boiler’s fuel valve to monitor boiler run-time and cycling• The timer bypasses the M2G every other day to provide a comparison of boiler’s run-time and

cycling behavior with and without the M2G• Bypassing the M2G on a alternating 24 hour basis minimizes confounding factors such as

weather as well as changes made within the building or to the boiler system

Ford Motor Company

• M2G pilots were carried out at Ford Motor Company

• Fairlane Plaza North (290 Town Center, Dearborn, MI)

Ford Pilot Results• Pilot commenced on October 1, 2011 and concluded November 30, 2011

Bypass 591.9Save 467.6M2G Savings 21.0%

Bypass 3.1Save 6.7

Bypass 3.4Save 10.1

Bypass 95.4Save 35.5

M2G Reduction 63%

Fairlane Plaza North - Fordland - 2011

Reduction in Cycling

Summary StatisticsEnergy Use per day (min.)

Average Run-time (min.)

Average Off-time (min.)

Average Cycles Per Day

No Effect On Comfort Level

Average Indoor Air Temperature

Bypass Active

73.6 °F 73.5°F

MotorolaEnergy Usage (Therms)

HDD Average Therms/HDD Energy Savings

Bypass 9,118 261.6 34.85 14.8%Save 6,819 229.6 29.70

Bypass 4.4Save 5.8

Bypass 7.1Save 11.6

Bypass 125.9Save 82.8

M2G Reduction 34%

Motorola - 2012

Reduction in Cycling

Summary StatisticsAverage Run-time (min.)

Average Off-time (min.)

Average Cycles Per Day

University of GeorgiaCenter for Applied Genetic Technologies

Location Building Size Boiler Make Boiler Output

Athens, GA 67,160 sq. ft. (2) Weil McLain 2,713,000 Btu/hr

UGA Preliminary Results• Pilot commenced on March 28, 2013 and concluded May 6, 2013

Average Run Time per Day HDD Run Time/HDD Energy Savings Bypass 402.8 min. 111.5 3.6 min. 16.7% Save 389.1 min. 128.7 3.0 min.

Bypass 1.3Save 3.0

Bypass 3.4Save 8.0

Bypass 153.1Save 64.9

M2G Reduction 58%

UGA - CAGT - 2013

Reduction in Cycling

Summary StatisticsAverage Run-time (min.)

Average Off-time (min.)

Average Cycles Per Day

UGA Boiler Cycling

0

50

100

150

200

250

3/22

/13

3/27

/13

4/1/

13

4/6/

13

4/11

/13

4/16

/13

4/21

/13

4/26

/13

5/1/

13

5/6/

13

5/11

/13

Num

ber o

f Cyc

les p

er D

ay

Center for Applied Genetic Technologies

No Effect On Comfort Level

Average Indoor Temperature

Bypass Active

CAGT 71.5 °F 71.6°F

Internal Revenue ServiceAtlanta Distribution Center

Location Building Size Boiler Make Boiler Output

Chamblee, GA 328,000 sq. ft. (1) Weil-McLain 6,000,000 Btu/hr

Internal Revenue Service

R² = 0.8141

R² = 0.9016

0

5,000

10,000

15,000

20,000

25,000

0 100 200 300 400 500 600 700

Cons

umpt

ion

(CCF

)

Heating Degree Days

Pre-M2G

M2G

IRS Building – Chamblee, Georgia CCF HDD CCF/HDD Energy Savings

Pre-M2G 76,166 1,452 52.5 18.7% M2G 88,626 2,077 42.7

Implementation (Next Steps)• Identify potential boilers

- Hydronic, space-heating boilers

- Closed-loop (No domestic hot water)

- No steam boilers

- No electric boilers

• Prepare Boiler Audit Form

• Gather gas spend bills from previous year- Determines financial numbers (ROI, IRR, etc.)

• Contact Greffen Systems

Customer:Date: Number of Boilers Customer Contact Name:Site Address:Boiler Location:

Boiler 1

Boiler MakeBoiler Model

Boiler Serial NumberPower Input Rating (BTU/hr)

Set Point TemperatureTemperature Differential

Boiler Type e.g. Atmospheric/Forced

Draught/Modulating/Water Heater/Modular/Other

Burner Control e.g. Honeywell 7800 (blue),

Fireye (red), etc

Make: Please list all equipment served by the gas meter for the boiler(s):

Please describe the make and model of BMS if applicableModel:

Does the site have a BMS controlling the boilers?

PRELIMINARY BOILER ROOM AUDIT FORM

Please either (1) fax completed form to: 678-550-5200 or (2) email: frank@greffensys.com

Boiler 2Boilers

BMS (Building Management System)

All information supplied will be treated as strictly confidential and will not be passed on to any third partiesPlease provide all information requested in the green cells.

Boiler Make Model and BTU rating can be found on a metal plate on the side of the boiler

Greffen Systems, Incorporated

Contact:Frank SalenskyChief Executive Officer394 Settlement LaneAlpharetta, GA 30004678-233-7724frank@greffensys.com

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RL Deppman

APPLYING CONDENSING BOILERS

Presented by: Josh Looper

deppmann.com | 800.589.6120

Today’s agenda

Applying Condensing Boilers

• Applying Condensing Boiler Technology

• Using Controls to Optimize Efficiency

What types of energy are we using?

Major Hydronic equipment energy costs• Boilers

• Gas$121,000

• Electricity $1,000

Applying Condensing Boilers

• Pumps

• Electricity$2,400

What does a 5% improvement gain us?

Major Hydronic equipment energy Savings• Boilers

• Gas $ 6,050

• Electricity $ 50

Applying Condensing Boilers

• Pumps

• Electricity$ 120

Applying Condensing Boilers

WHAT IS CONDENSING?

Combustion process

• Air + Natural Gas + Spark

• =

• Heat + CO2 + CO + NOX + H2O

Applying Condensing Boilers

Combustion process

Applying Condensing Boilers

1000 Btu/lb

How do we condense

Applying Condensing Boilers

Dew point

Applying Condensing Boilers

System Discussion

Applying Condensing Boilers

Primary / Secondary Variable

Applying Condensing Boilers

Primary / Secondary Variable

Applying Condensing Boilers

Primary variable / Secondary Variable

Applying Condensing Boilers

Primary variable / Secondary Variable

Applying Condensing Boilers

Primary variable / Secondary Variable

Applying Condensing Boilers

Primary variable / Secondary Variable

Applying Condensing Boilers

Primary variable

Applying Condensing Boilers

Primary variable

Applying Condensing Boilers

Primary variable

Applying Condensing Boilers

Applying Condensing Boilers

CONTROLS & EFFICIENCY

cycling efficiency

Turndown ratio

• 2:1

• 5:1

• 10:1

• 20:1

Applying Condensing Boilers

Minimum firing rate

• 1500MBH

• 600MBH

• 300MBH

• 150MBH

3000MBH INPUT HEATER

cycling efficiency

Applying Condensing Boilers

Cycling reduces boiler efficiency by 2-

7%!!!

Other items to look for

• Staging Controls

• Who Controls What

• O2 Trim

• Regular Maintenance

Applying Condensing Boilers

THANK YOU

127

2016DTE Energy EfficiencyProgram for Business

Adam ConstantinoOutreach Manager

128

129

Safety FirstExits

RestroomsOther site features

130

• 8:30 – 8:35 Introduction• 8:35 – 9:10 DJ Conley• 9:10 – 9:40 Performance Engineering Group• 9:40 – 10:00 Break/Networking• 10:00 – 10:35 Greffen Systems• 10:35 – 11:05 RL Deppmann• 11:05 – 11:25 DTE Energy Efficiency Program for Business

• 11:25 – 11:30 Closing Remarks• 11:30 Lunch and Networking

Agenda

131

Technical Presentations

132

DTE Energy Efficiency Program for Business

133

• Program Overview• Program Incentives• Boiler Incentive Opportunities• 2016 Program Catalog & Applications• Designated Trade Allies• Special Offers

Agenda

134

Program Overview

135

Program funding • Michigan Public Act 295 (2008): statewide “Energy Optimization Surcharge” added to all ratepayers’ bills to:

• Help customers save energy, manage costs.• Help reduce generation, offset new capacity.

• This “surcharge” is rebated through the program as cash incentives that:

• Target specific energy-saving equipment and technologies.• Encourage energy-efficiency building and systems design.

Program Overview

136

Since 2009:• More than $127 million in cash incentives has been paid to Michigan business customers.

• More than 41,000 projects have been completed.

Program Overview

*As of December 2016

137

The impact of saving energy• Our customers have realized savings of:

• 13 million Mcf in natural gas.• 5,000 GWh in electricity.• $400 million in total energy costs.

These energy savings translate into 4 million tons of CO2 not being pumped into the atmosphere.

Program Overview

*Household data based on estimates from the U.S. Energy Information Administration.*CO2 calculations based on U.S. Environmental Protection Agency guidelines.

138

For a customer to receive incentives• Qualified measures must be installed at facilities served by DTE

Energy.• Projects must involve a capital investment that results in an

improvement in energy efficiency of a system or building.• The equipment installed must be new and meet the specifications

spelled out in the Catalog.• For each site, there must be at least one meter that is on an

eligible rate schedule.• You must be in good standing with DTE Energy and not be a

Residential or Multifamily customer.

Program Overview

139

These do not qualify for an incentive• Customers who self-direct (and have opted out of the program)• Load shifting/demand limiting projects.• Renewable energy projects.• Power quality improvements.• Fuel switching projects.• On-site electricity generation.• Changes in operational and/or maintenance practices or simple

control modifications that do NOT involve capital costs.

Program Overview

140

Program Incentives

141

Three types of program incentives• Predetermined measures and incentives for the installation

of various energy efficient improvements.• Incentives typically average 20% to 50% of the incremental

cost.

Program Incentives

• New facilities/major renovations of existing facilities or change of use projects.

• Adding load.

• Capital investment projects that increase energy efficiency and are NOT eligible for a Prescriptive Incentive may qualify as a Custom Measure.

• Custom Incentives are determined on a case-by-case basis and are paid per unit energy saved (ex: $0.07/kWh and/or $4/Mcf).

Prescriptive

Custom

New ConstructionMajor Renovation

142

Prescriptive

Project Reservations

• Reservation Applications are not required for most Prescriptive projects, BUT they are highly recommended.

• A Reservation Application is required for certain measures: check the Application for details.

Custom

New ConstructionMajor Renovation

Reservation Applications set aside funds for your project to ensure availability when your project is completed and you submit your Final Application. Here are our guidelines:

If you submit a Reservation Application, do NOTstart your project until you receive a Reservation Letter!*

*Could take 4-6 weeks to receive the letter

• A Reservation Application is required for all Custom projects.

• A Reservation Application is encouraged for all New Construction and Major Renovation projects.

Program Incentives

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Prescriptive• Pre-determined measures with specific energy savings and

cash incentiveso Categories include:

• Lighting• HVAC Electric• Miscellaneous Electric• Process Electric• Food Service Electric

Prescriptive

Program Incentives

• HVAC Gas• Hot Water & Laundry• Insulation• Process Gas• Boiler/Furnace Tune-up• Food Service Gas

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Natural Gas project exampleK-12 SchoolReplaced six aging space heating boilers with high efficiency models.• Total project cost....................• Total incentives......................• Project cost after incentives…• Total Mcf saved/yr..................

$300,000$26,600$273,400500

Prescriptive

Program Incentives

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Custom Incentives Capital investment projects that increase energy efficiency and are NOT eligible for a Prescriptive Incentive may qualify as a Custom Measure.

• Custom Incentives are determined on a case-by-case basis and are paid per unit energy saved (ex: $0.07/kWh and/or $4/Mcf).o Examples include:

• Heat recovery• Lighting retrofits not 1 for 1

Custom

Program Incentives

146

Natural Gas project example

Total project cost...................• Total incentives......................• Project cost after incentives... • Total Mcf saved/yr.................•Simple payback.....................

$344,985$32,488$312,4978,1228.5 years

Custom

Program Incentives

Heavy Industry

Replaced aging hydraulic controls

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New Construction/Major Renovation:• New facilities/major renovations of existing facilities/change of use.• Adding load.• Incentives are offered in three areas:

• LEED Design Review Assistance:• $1,500 for LEED project certification.

• Systems Approach:• Pre-determined measures designed to optimize efficiency of individual systems.• LEED Whole Building Approach:

• Based on LEED certification.• Three levels of incentives based on four LEED certification levels.

New ConstructionMajor Renovation

Program Incentives

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Boiler IncentiveOpportunities

149

Incentive Opportunities: Boilers

Incentive Opportunities

Measure Incentive Unit

Boiler Modulating Burner Control Retrofit $1,250.00 BoilerBoiler Water Reset Control Retrofit $0.50 Input MBHHigh Efficiency Boilers (Space Heating) $1.00 Input MBHBoiler 02 Trim Control $0.15 Input MBHLinkageless Boiler Control $0.25 Input MBHBoiler Linkageless Controls and O2 Trim Control $0.35 Input MBHHigh Eff. Indirect Domestic Hot Water Heating System 90% Efficient

$1.25 Input MBH

Mid Eff. Indirect Domestic Hot Water Heating System 84% Efficient $0.75 Input MBHPipe Wrap – Steam Boiler $5.00 Linear FootPipe Wrap – Steam Boiler Condensate Return $2.00 Linear FootPipe Wrap – Hot Water Boiler $3.00 Linear Foot

Existing retrofit incentive opportunities

150

Incentive Opportunities: Boilers

Incentive Opportunities

Measure Incentive Unit

High Efficiency Process Boiler – Water $1.00 Input MBHHigh Efficiency Process Boiler – Steam $1.00 Input MBHSpace Heating Boiler Tune-Up 110-500 Input MBH $100.00 BoilerSpace Heating Boiler Tune-Up 501-1,200 Input MBH $200.00 BoilerSpace Heating Boiler Tune-Up >1,200 Input MBH $350.00 BoilerProcess Boiler Tune-Up ≤ 3,000 Input MBH $350.00 BoilerProcess Boiler Tune-Up > 3,000 - < 6,000 Input MBH $1,000 BoilerProcess Boiler Tune-Up ≥ 6,000 - < 10,000 Input MBH $1,500 BoilerProcess Boiler Tune-Up ≥ 10,000 Input MBH $2,000 Boiler

Existing retrofit incentive opportunities

151

2016 Program Catalog and Applications

152

Program Catalog• Includes specifications and details for

every Prescriptive incentive measure.

• Includes specifications and details on how to submit a Custom project.

• Use it as a desktop reference for all your projects.

2016 Program Catalog and Applications

153

There are five prescriptive electric measure categories:

• Lighting• Miscellaneous• Process• Food Service/Refrigeration• HVAC

There are six prescriptive gas measure categories:

•HVAC•Insulation•Process•Hot Water & Laundry•Boiler/Furnace Tune-up•Food Service

2016 Program Catalog and Applications

If a project involves measures from at least two of the measure categories and no single category is more than 75% of the total value of the Application, the customer may qualify for a 20% Multi-Measure bonus on the entire Application.

154

Measures marked with MM are measures that may qualify for the Multi-Measure Bonus on a project with both electric and natural gas.

2016 Program Catalog and Applications

155

2016 Program Catalog and Applications

Gas-Electric Project SummaryProject Incentive Percentage of

IncentiveSavings:* kWh Mcf

Lighting $1,665 35.5% 321,202

HVAC Electric $1,025 21.85% 298,372

HVAC Gas $2,000 42.64% 309.2

Incentives $4,690 619,574 309.2

Multi-Measure Bonus $938

Total Incentives $5,628*First-year savings estimated

Multi-Measure Bonus Example

156

SpecificationsDetailed specifications for every prescriptive measure offered under the 2016 Program.

2016 Program Catalog and Applications

157

Program ApplicationUse it as a:• Reservation Application

and a• Final Application

NOTE: Funds must be reserved for all customprojects and for certain prescriptive measures.

We encourage you to submit a Reservation Application for all prescriptive projects.

2016 Program Catalog and Applications

158

Prescriptive projects: • There are worksheets for every

prescriptive measure.• In the interactive PDF

Application, calculations are made automatically.

• Check the Michigan-Madebox(es) for measures that meet the bonus criteria.

2016 Program Catalog and Applications

159

The interactive PDF will:• Automatically calculate each item’s

incentive – and total those numbers at the bottom.

• Automatically account for payback requirements (electric and gas) and the 50% capping limit.

• Automatically allocate the incentives proportionally to each eligible item for Multi-Measurecalculations on Page 6 (you mustcheck the category, such as “Lighting”).

2016 Program Catalog and Applications

Custom projects:

160

Electronically submit your Reservation Application and/or your Final Application.Automatically:

• Your email will be launched,• Our email address will be inserted,• The subject line will be entered

indicating whether it is a Reservation or Final Application and

• Your Application will be attached.At that point, attach any other supporting documentation.

Note: check the blue boxes to ensure that your incentives have been entered correctly.

$1

$1

2016 Program Catalog and Applications

161

About your Final Application:• Your Final Application must be

submitted within 60 days of project completion , reservation end date or by Nov. 30, 2016 – whichever comes first.

• Failure to include all supporting documentation at the time of submission could result in cancellation of your Application.

2016 Program Catalog and Applications

162

Designated Trade Allies

163

Designated Trade Ally• A Designated Trade Ally is a contractor

specially trained in how to access our Program and use the Application to maximize the Program’s benefits for DTE customers.o They include: Contractors, suppliers,

designers and consultants.

Designated Trade Allies

164

DesignatedTrade Allies

• Go to dteenergy.com/findacontractor

• Click on Energy Efficiency Directory link.

Designated Trade Allies

How Customers find a Designated Trade Ally

165

DesignatedTrade AlliesDesignated Trade Allies

How Customers find a Designated Trade Ally• You can then

search by Location (city or ZIP) and Program Type

Or

• You can search by Contractor Name

• Once you narrow your search, you can view a list of contractors in your area

166

DesignatedTrade AlliesDesignated Trade Allies

How Customers find a Designated Trade Ally

167

Special Offers

168

Michigan-Made bonus• 15% bonus for certain installed

equipment that is 50% manufactured and/or assembled in Michigan (excluding packaging).

o Some Prescriptive measures are not eligible.

o Custom projects are not eligible.

o Look for the check box on the Application next to qualified measures.

The Michigan-Made affidavit can be downloaded at: dtetradeally.com

Special Offers

169

Multi-Measure bonus• 20% bonus on multiple categories

submitted on the same Application – when no single category is more than 75% of the Application.o Our Catalog highlights measures (MM)

that appear in both electric and gas that may qualify.

This Fact Sheet can be downloaded at: dtetradeally.com

Special Offers

170

Contractors vs.Designated Trade Ally

Gas-Express Pay• This program is designed to fast track the installation of energy-

efficient equipment in the businesses of eligible DTE customers.• For DTE customers: a simple way to have energy-efficient

equipment installed in their businesses without the paperwork of our main incentive program.

• For participating DTE Designated Trade Allies: a streamlined process designed to fast track incentive payments directly to you —providing a further incentive to work with customers on project costs.

• For a limited time, Designated Trade Allies can receive a 40% Multi-Measure Bonus on qualifying Gas-Express projects.

• Contact us for more details.

Special Offers

171

Building Operator Certification ProgramProgram offers tuition reimbursement:

o Gas or Electric Certification: $650o Combined Gas/Electric: $950

• Only DTE Energy customers with facilities larger than 50,000 square feet are eligible.

• Building professional must attend, pass and become certified in Level I or Level II certification course administered by the Midwest Energy Efficiency Alliance (MEEA).(Other conditions apply; see Application for details)

This Application can be downloaded at: dtetradeally.com

Special Offers

172

Financing from Michigan Saves

This Worksheet can be downloaded at: dtetradeally.com

Special Offers

• 0% financing on up to $50,000 for up to 36 months

• 2.99% financing on up to $150,000 for up to 60 months

• 1.99% financing on up to $150,000 for up to 60 months for municipalities and K-12 schools

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In Summary

• Program Overview• Program Incentives• Boiler Incentive Opportunities• 2016 Program Catalog & Applications• Designated Trade Allies• Special Offers

174

If you have questions, please contact our office

Email: saveenergy@dteenergy.comPhone: 866.796.0512 (press option 3)

Fax: 313.664.1950Website: dteenergy.com/savenow

Website: dtetradeally.com

www.linkedin.com/in/dteenergysaveenergy: