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The University of Vermont Physical Plant Department Engineering Intern Program

The University of Vermont Physical Plant Department Engineering Intern Program. Contributors Salvatore Chiarelli, Director of Physical Plant Richard Wolbach, Energy & Utilities Engineer Travis Rohlin, Controls & Automation Engineer and UVM Student, Graduate / Electrical Engineering

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The University of Vermont Physical Plant Department Engineering Intern Program

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  1. The University of VermontPhysical Plant DepartmentEngineering Intern Program

  2. Contributors • Salvatore Chiarelli, Director of Physical Plant • Richard Wolbach, Energy & Utilities Engineer • Travis Rohlin, Controls & Automation EngineerandUVM Student, Graduate / Electrical Engineering • Evan Malina, UVM Student / Mechanical Engineering • Josh Hogan, UVM Student / Civil Engineering • Nick Chiarelli, UVM Student / Mechanical Engineering UVM PPD – Engineering Interns 10•5•2009

  3. UVM PPD – Engineering Interns 10•5•2009

  4. NEW OLD Dudley H. Davis Student Center -- 2007 Grassmount -- 1804 The University of Vermont has an extremely diversified group of campus buildings and associated mechanical / electrical systems. UVM PPD – Engineering Interns 10•5•2009

  5. IMAGINE ... Having A Source Of Smart, Ambitious, Engineering Talent Eager to Take On Assignments, Write Reports and Not Give Any "Back Talk"! UVM PPD – Engineering Interns 10•5•2009

  6. IMAGINE ... If This Campus Resource Was Infinite and A "Stones Throw" Away -- Reasonably Priced! UVM PPD – Engineering Interns 10•5•2009

  7. UVM Physical Plant Department is fortunate to have this on-campus resource and we are successfully "tapping" into it ... UVM PPD – Engineering Interns 10•5•2009

  8. UVM PPD – Engineering Interns 10•5•2009

  9. Joshua Hogan – (Civil Engineering) • Restoration Analysis Projects: • Williams Hall -- Thermal Imagery • Increasing Heating Efficiency • Johnson House -- Joist Analysis • Structural Integrity of Historic Buildings UVM PPD – Engineering Interns 10•5•2009

  10. Thermal Imagery • Replaced original windows and framing • Photographed exterior west windows • Compared with images of original windows UVM PPD – Engineering Interns 10•5•2009

  11. Thermal Imagery BEFORE • Photograph windows from interior, as well. • Heat transfer is visible around window frame. • Specific sections of window framing cause drafts. AFTER UVM PPD – Engineering Interns 10•5•2009

  12. Thermal Imagery • Restoration was a UVM project necessity. • Difficult to measure savings in our older buildings. • Reduced need for personal heaters and A/C units in offices. UVM PPD – Engineering Interns 10•5•2009

  13. Joist Analysis • Constructed in 1806 • Structure moved twice -- in 1907 and again in 2005. • Building has seen three (3) foundations in approximately 100 years. UVM PPD – Engineering Interns 10•5•2009

  14. Joist Analysis • Stress on both beam and joist members caused “deflection.” • Damaged drywall in 1st story. • Beams are over 200 years old! UVM PPD – Engineering Interns 10•5•2009

  15. Joist Analysis • Analyze individual beam and joist members • Understand optimal support placement • Prevent further deflection in main support members UVM PPD – Engineering Interns 10•5•2009

  16. UVM PPD – Engineering Interns 10•5•2009

  17. Travis Rohlin – (Electrical Engineering) • Four (4) Major Projects: • Renovation Control Design • Utility Sub-Metering Project • Campus Wide Global Scheduling • BMS “Point Descriptor” Upgrades UVM PPD – Engineering Interns 10•5•2009

  18. Renovation Design • Given Medical Bldg. -- Lab Renovation Project: • Needed new controls for lab, fume hood and office space. • Designed controls system for the laboratory. • Purchased and installed all equipment in space. UVM PPD – Engineering Interns 10•5•2009

  19. Renovation Design • Project Responsibilities: • Drafted Overall Design • Assisted with Installation and Testing UVM PPD – Engineering Interns 10•5•2009

  20. Return on Investment • Gained valuable experience for the next renovation project. • Worked on other UVM campus lab renovations. • Was given increased responsibility on each new renovation project. UVM PPD – Engineering Interns 10•5•2009

  21. Utility Metering • Utility Metering Project: • Davis Center • Utilities charged by square footage -- not usage. • Lots of sub-users, very different consumption types. • Use existing BMS sensors to monitor control points in field. • Water, heating, cooling (chilled water) & natural gas. UVM PPD – Engineering Interns 10•5•2009

  22. Utility Metering • Located system control points with each individual user’s utilities • Logged system control points to capture the data • Exported data using a ODBC type Driver UVM PPD – Engineering Interns 10•5•2009

  23. Utility Metering • Imported logged data into Microsoft Access. • Microsoft Access chosen for ease of reports. • Finally, a tutorial was created to aid the UVM PPD business group in creating utility reports for annual or semi-annual type reporting. UVM PPD – Engineering Interns 10•5•2009

  24. Return on Investment • The project cost was labor intensive. • Customers were billed on actual usage. • This project resulted in; • time saved for customer billing, • better UVM customer relations, • less potential turnover, • and free advertising / marketing! UVM PPD – Engineering Interns 10•5•2009

  25. Global Scheduling Effort to conserve energy at UVM: • HVAC units use a lot of energy • Set-back unoccupied areas • Changed BMS unit set points • Automated the overall process Changed the set point daily or for special cases (e.g., holidays) Note: BMS = “Building Management System” UVM PPD – Engineering Interns 10•5•2009

  26. Global Scheduling • Used controls systems to automate control process • Honeywell system • Combined units within similar “global” schedules • Determined when areas or spaces are unoccupied UVM PPD – Engineering Interns 10•5•2009

  27. Return on Investment • The project was primarily labor based • Learned “scheduling” feature • Organized BMS schedules • Fine-tuned point management • UVM Savings • On-going savings • Estimated at $77,662 a year! UVM PPD – Engineering Interns 10•5•2009

  28. UVM PPD – Engineering Interns 10•5•2009

  29. Nick Chiarelli – (Mechanical Engineering) UVM Central Heating Plant Projects: • Boiler Blowdown Recovery System • Insulation or Thermal Blankets UVM PPD – Engineering Interns 10•5•2009

  30. What is blowdown? • Boilers generate unwanted dissolved solids from normal operation. • These solids build up on the water surface. When this level gets too high, a “blowdown” is necessary to clean the water. • The top three (3) inches of water are sprayed off to get rid of most of the solids. • Without this, normal boiler operation would be highly inefficient. UVM PPD – Engineering Interns 10•5•2009

  31. Two (2) Blowdown Types Surface Blowdown: The constant flowing blowdown which removes dissolved solids from the steam drum. Bottom Blowdown: Performed a few times a week manually to remove unwanted solids from the mud drum. UVM PPD – Engineering Interns 10•5•2009

  32. Where does it go …? • A blowdown tank holds all of the water and dumps it out the drain at very high temperatures. UVM PPD – Engineering Interns 10•5•2009

  33. Problems? • A lot of energy is being thrown down the drain in this process. • When the 370°F water hits the blowdown tank, only 15.8% is flashed to steam and actually used in the “heating system.” • The other 84.2% of this hot, energy filled water is disposed of down the drain. UVM PPD – Engineering Interns 10•5•2009

  34. Solution? • Create a heat exchange system to capture the lost heat and put it back to use in order make the whole heating system process more efficient for UVM. • Pre-heat the incoming City makeup water which is around 45 °F to 65 °F; when it enters the UVM Heat Plant system. • Cool down the dirty blowdown water to make for a more “environmentally friendly” disposal and to use less or no City makeup water, in the overall process. UVM PPD – Engineering Interns 10•5•2009

  35. Condensate Return 60,785 lb/hr 140°F-160°F 7,313 gal/hr City Makeup Water Condensate Tank Deaerator 15 psig 245° F 5,331 lb/hr 656 gal/hr 45°F-65°F Atmospheric pressure 140°F Steam 15 psig 473 lb/hr Feedwater 66,589 lb/hr 8,011 gal/hr 245°F 15.8% Flashed Steam Blowdown Line Blowdown Tank 200°F-300°F 2,993 lb/hr 360 gal/hr 300°F Wasted hot water quenched to 120°F using city water Steam to Campus 2,520 lb/hr 303 gal/hr 429,473 BTU/hr = $3.41/hr = $29,834/yr 63,596 lb/hr 215 psig

  36. Condensate Return 60,785 lb/hr 140°F-160°F 7,313 gal/hr Heated City Makeup Water Condensate Tank Deaerator 15 psig 245° F 5,331 lb/hr 656 gal/hr 125°F-165°F Atmospheric pressure 160°F-180°F Steam 15 psig 473 lb/hr **Increase Temp By 80°F-100°F 66,589 lb/hr 8,011 gal/hr 245°F 15.8% Flashed Steam Feedwater Blowdown Line Blowdown Tank 2,993 lb/hr 360 gal/hr 300°F 200°F-300°F Heat Exchanger Colder Waste Water w/o Quenching Steam Out 63,596 lb/hr 215 psig Cold City Makeup water 5,331 lb/hr 656 gal/hr 45°F-65°F

  37. Final Project Outcome • A unit was found which fit our situation perfectly made by Penn Separator tm. • The Penn Separator tm “Flash Economizer” is a blowdown tank with a built in stainless steel heat exchanger. • With a cost of $12,510 and an estimated savings of $41,417 in both natural gas and water, the simple payback period for this project is under 4 months! UVM PPD – Engineering Interns 10•5•2009

  38. Insulation Blankets – Insultech tm • Insulation on pipes is necessary to hold in the heat of the steam or hot water. • Straight pipes have a fiberglass based insulation which is not easy to take on and off by UVM staff. • For places where there is a need to get your hands and work, Insultech tm makes removable (with Velcro straps) thermal type blankets to help save energy in these places that would otherwise be bare metal. UVM PPD – Engineering Interns 10•5•2009

  39. Before After UVM PPD – Engineering Interns 10•5•2009

  40. What we have so far … • Shannon Enterprises conveyed an energy audit or survey proposal for UVM, last year. • Shannon Enterprise team went to every mechanical room on campus to custom fit each and every valve. • The decision was made to buy the blankets for the forty-four (44) pressure reducing valves on campus (not including the Central Heat & Chilled Water Plant). • Covering these forty-four (44) valves has saved UVM an estimated $12,000 in fuel savings, so far in a fiscal year. UVM PPD – Engineering Interns 10•5•2009

  41. UVM PPD – Engineering Interns 10•5•2009

  42. UVM PPD – Engineering Interns 10•5•2009

  43. What we could be saving … • Insultech’s report also included the remaining 341 valves on campus -- not including the Central Heat & Chilled Water Plant. • Heat is being lost, every single second, out of these non-insulated valves. UVM could be saving energy and decreasing our fuel bill by $173 per hour or about $63,000 per year! UVM PPD – Engineering Interns 10•5•2009

  44. Still more potential … • Thermal blankets are available for facility applications other than simply pipes and/or valves. • The steam and mud drum doors reach over 400 degrees F and would be a great place to save even more energy! • These insulators are a great investment, especially with such a quick payback. UVM PPD – Engineering Interns 10•5•2009

  45. UVM PPD – Engineering Interns 10•5•2009

  46. Evan Malina – (Mechanical Engineering) • Energy Savings Projects: • Bailey-Howe Library Lighting Projects • Daylight Sensors • Super T-8 Fluorescent Stack Lighting • Gucciardi Fitness Center Window Film Application (3M tm) • Campus “Revolving Door” Analyses UVM PPD – Engineering Interns 10•5•2009

  47. Library Lighting • Installed Daylight Sensors (circled in picture, at left) • Replaced 59 Watt and 32 Watt bulbs with 51 Watt and 28 Watt Super T-8 fluorescent lamps, respectively. Note: UVM’s Bailey-Howe library is “major electrical user.” It is always open, and the lights are always on for both student use, as well as campus security measures. UVM PPD – Engineering Interns 10•5•2009

  48. Daylight Sensors • Installed Daylight Sensors (circled in picture, at left) • Daylight sensors turn off Library interior, perimeter lights when the sensors read at least 5.0 footcandles • Sensors blend well with the ceiling tiles • Savings per hour; • 5.76 kW • $0.75 (assume $0.14 per kWh) • 10 hrs. / day, 365 days / yr. saved UVM PPD – Engineering Interns 10•5•2009

  49. Daylight Sensors • Sensor installation project was about $16,000 (labor and materials) • Expected Utility Rebate of $2,000 from Burlington Electric Department • Savings of around $2,600 per year • Simple Payback for UVM: 5.4 years UVM PPD – Engineering Interns 10•5•2009

  50. Stack Lighting Replacement • New Philips Brand Bulbs – Super T-8 • 8 ft. (51 Watt) and 4 ft. (28 Watt) • Replaced old 59 W and 32 W types • Bailey-Howe Library has 350, 8 ft. and 85, 4 ft. fluorescent type lamps • High use location – 14 hrs. / day, 365 days / yr. (primarily “lighting load”) • Estimated UVM savings of 3.34 kW UVM PPD – Engineering Interns 10•5•2009

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