4/22/2015
Regenerative Media Filters
Engineered For Sustainability :
• 90% Less Water and Waste
• 30% Less Fuel & Chemicals
• 75% Less Construction (space and labor)
• 50% Less Electrical Power
• Superior Water &Air Quality
Rapid Return on Investment


Regenerative filter will typically pay
for itself in as little as 2 to 5 years.
Cost Savings Analysis tool can help
project your own ROI.
1
4/22/2015
The Flex Tube



½” T304L stainless steel coil
wrapped in a high strength
polyester weave
Gains 1/8”average media
coating per side creating
over 0.78 ft² of surface area
per 4ft tube
9 to 12 times the filter area of
an equivalent sand filter
The “Bump”

Filter Tubes in Precoat State



Air is quickly exhausted
from bump tire
Perlite is loosened from
flex tubes as tube sheet
descends
Bump tire re-inflates
Forced water expands
flex tubes enhancing
perlite release
2
4/22/2015
How it Works:
Regeneration
Regeneration
Filter Tube



Benefit #3: Save
Perlite forms 1/8” layer
of media on flex tubes
Filtered particulate is
captured on outer
surface of perlite
Bump releases perlite
to expose fresh media
surface area
on Construction
Regenerative filters typically require just ¼ of the space needed for
equivalent high rate sand filters.This example represents a savings of 164 ft²
19 ft
6 ft 8 in
Total Footprint: 58 ft²
11 ft 8 in
Total Footprint: 222 ft²
8 ft 8 in
One 49” dia. Defender
does the same work as four
48” X 84” sand filters!
3
4/22/2015
Benefit #3: Save
on Construction
Construction Cost Savings:
 No backwash holding tank
 Smaller waste line to sewer
 Reduced sewer permitting fees
 Local backwash to waste flow rate restrictions
are no longer an issue
 Operating wt as low as 2 ton vs. 20 ton w/ sand
 Regenerative filters helps earn LEED points…
Related Labor Savings

Installation
 General
construction
 Rigging
 Handling
 Piping
 Media loading

Operation
 Media replacement
 Less routine
maintenance
 Reduced long-term
maintenance
4
4/22/2015
Benefit #5: Improve
Health & Safety:



Water Quality
 Particle removal
down to 1 Micron
 Removes 99.95% of
crypto in a single pass
 Improves UV efficiency
Air Quality
Building Integrity
Water Quality
How Small is
a Micron?
The average
human hair is
roughly 100
microns wide!
Questions and Answer
Norm Hamelin
Aquatic Source
Aquatic Specialist
AFO & CPO certified
5
4/22/2015
Energy Saving Strategies for Pools
• Pools can be a great school and community asset, but they do require resources to maintain them. From maintenance to energy usage, pools can be expensive to operate. There are ways to reduce these costs, however particularly by utilizing good management strategies. Learn how to leverage operational practices and various types of equipment to significantly lower energy consumption with your pool.
• Energy savings thru pool room equipment integration
• Improved water quality
• Resulting improved air quality reduces demand for fresh
makeup air
• Not having to heat as much air saves significantly on
heating costs
• Significant savings on electric, natural gas, and water
• Impressive ROI with continued energy savings thereafter
• Incentive grant money often can improve the ROI
1
4/22/2015
$120,000.00
$100,000.00
$80,000.00
$60,000.00
$40,000.00
$20,000.00
$0.00
2010
2012
Billing
2
4/22/2015
Symptom: Poor air quality due to water chemistry at indoor pools
Problem: Chlorine disinfection by-products (DBP’s) off-gas in a corrosive vapor
Solution: Add UV technology to continuously reduce DBP’s in the filtered water
Added benefit: Energy savings
Improving the water results in improved air quality
If facilities use significantly more fresh make-up air than ASHRAE 62.2 minimums,
serious energy savings can result from reducing the volume of make-up air
Integrating technologies to automate to process
Chemical controller continuously measures (DBP’s) in water, adjust energy levels of
the UV, VFD’s, and HVAC supply. Improved filtration reduces water wasted by 80%
3
4/22/2015
UV Benefits in Aquatics
Naturally controls chloramines
Indoor pools
High level disinfectant
Chlorine resistant pathogens like “Crypto”
The Facilities Department of USA Swimming strongly
recommends that all pools, both new and existing,
have UV systems installed…When compared to
chlorine feeder systems, Ultra Violet systems involve a
higher initial capital cost. However, over the life of the
pool Ultraviolet technologies reduce the on-going
operating and maintenance costs. This can be
significant.”
Mick Nelson, USA Swimming Facilities Department
4
4/22/2015
Cost Savings
Energy – natural gas, water, & electrical (when adding VFD’s)
Corrosion – HVAC, railing, deck equipment, light fixtures, swimsuits
Chemicals – no shocking required, pool open longer, lower TDS levels
Reduced risk – RWI outbreak, athletic asthma, respiratory issues
Maintenance – labor, service
5
4/22/2015
Energy Management
Integrating UV, VFD’s, and controllers with the HVAC
•
•
By controlling chloramines in the water, we can reduce fresh make-up air
Most indoor pools bring in many times more fresh air than what is
required by ASHRAE 62.2
•
Presented at the 2013 World Aquatic Health conference
6
4/22/2015
The History of Variable Frequency Drives
‐ VFD’s have been used for more than 30+ years
‐ Prominent in Europe for decades
‐ Prior to 1990’s, primarily used in just heavy industrial applications in the United States
‐ 1/3 of the world’s electrical energy is consumed by electric motors in pump, fan & compressor applications
‐ Due to increasing energy costs & improved performance technologies, VFD’s are now being integrated on numerous applications, especially in aquatics.
1
What is a Variable Frequency Drive?
A VFD is an electronic device that:
‐ Controls the speed of an electric motor by varying the supply frequency (Hz) (Converts AC to DC inverts back to AC)
‐ Provides continuous control, matching motor speed to the specific work demand needed
‐ VFD’s are sized based on amps in conjunction supply voltage (208/230V or 460V)
‐ There are 63 manufacturers of VFD’s in the world today
‐ Most VFD’s are not designed / suited for pool mechanical rooms
2
1
4/22/2015
How does a Variable Frequency Drive work?
Pulsed Width Modulated output
(Variable Frequency)
Sine Wave Power (AC) 60 Hz
Supply Voltage
Variable
Frequency
Drive
3
What should an Aquatic VFD do for you?
‐
‐
‐
‐
Be durable, have longevity
Protect your equipment
Easily operated / pool specific
Maximize your energy savings potential w/out compromising water quality
4
2
4/22/2015
Durable & Longevity
Environment
Pool Room
Chemical Gases likely
Pool Room
No Chemical Gases
NEMA 12
NEMA 1
5
Why NEMA 12?
Pool Room
Chemical Gases are almost a certainty
NEMA 12 - essential
NEMA 1 - unsuitable
Corrosion to VFD circuit board tracks
6
3
4/22/2015
Protects your equipment
7
Soft start / stop the motor
‐
‐
‐
Reduces the thermal/mechanical stress
Eliminate water hammer, protect your pipes and plumbed equipment
Significantly reduces starting current (Amps)
8
4
4/22/2015
“Brownouts”
Under voltage is defined as a condition where the applied voltage drops to 90% of rated voltage, or less, for at least 1 minute.
Low‐voltage conditions occur when a facility asks for more power than the line can deliver.
Low voltage means higher current and increased heat in the motor
9
Excessive heat is a problem for motors because:
‐ insulation life is halved for every 10°C increase in temp
‐ at the same time, the temperature of the winding will rise 10°C to 15°C for each 10% drop in voltage. Under voltage events that last long enough to increase winding temperature cause irrevocable damage to winding insulation and unexpected failures later. 10
5
4/22/2015
Pump Cavitation If we move too far right on the curve, the
water supply into the pump becomes
insufficient to avoid boiling within the
volute. The high pressure bubbles
explode and eat away at the pump
impeller and volute. Partially closing the
discharge valve can prevent this but this
technique wastes energy!
4 Months Old Cavitated Impeller
6 Months Old Cavitated Impeller
(Public School, St. Louis, MO)
11
Pump Dry Run / Dead Head Protection A large resort hotel in Maui recently suffered $100K in damage when an operator inadvertently closed a discharge valve on the pump. The pump continued to run, the pump melted and the below grade pump room flooded.
The shaft power load curve monitoring function that would have detected the dead head condition and immediately shut down the pump.
12
6
4/22/2015
Lightning Strikes
Lightning damage to circuit board
When Lightning strikes a building, it is quite common for any electronics within the building to be damaged or destroyed.
13
14
7
4/22/2015
Lightning Arrestor
Certain areas of the Country experience recurrence of lightning activity. Electronic equipment connected to power supply
lines that are hit by a lightning strike, is inevitably destroyed unless protected by a Lightning Arrestor.
Lightning Arrestor
installed in
Bypass Panel if
supplied as an
Option in project
Lightning Arrestor
installed in base of
VFD if no Bypass
Panel Option
included in project
15
Bypass Panel
Should the VFD ever need to be removed for service, the Bypass Panel will allow the Operator to continue running the
pump by means of selecting Bypass from the door mounted key switch
Eco-Flow Controller
built into door of
Bypass Panel
VFD / Bypass
Selector Switch
with key lock
NEMA 12 Panel
Bypass Contactor
with Motor
Overload
16
8
4/22/2015
Ease of VFD Operation
‐ Pool Specific
17
• VFD’s are extremely flexible and can be applied to many applications
• The Pool pump is a relatively simple application
• VFD Instruction Manuals are typically have 200-300 pages in length
• Most VFD’s have 250-300 parameters that can be adjusted
• Most pool room operators are not familiar with VFD’s
18
9
4/22/2015
19
VFD programming is complex and comprises literally hundreds of menus to wade through.
However some vfd’s have a simpler method of operation.
Enter Password
Set Date
Set Time
Set Motor Details
Controller
Set Motor Supply Voltage
Set Motor HP
From Motor Nameplate
Set Motor Amps
Set Motor RPM
Set Max Speed Pump to run at
Set Backwash Speed
Set Backwash Duration
Single Wire Modbus Communication
Select ‘run at fixed speeds’
Select run at ‘Constant Flow’
Set one fixed speed or two
fixed speeds
Select run at Constant Flow
with fixed Night time speed
20
10
4/22/2015
Maximize Your Energy Savings
21
Engineering & Design of a Pool
• Engineers are cautious when sizing, pipes, valves and pumps
• Flow rates are difficult to determine at the design stage
• Future facility expansion is sometimes factored in
• Control valves are typically used to adjust flow rates after the pool is built
• Energy efficiency has not been so important in years past
22
11
4/22/2015
Controlling the flow rate with a valve
is like driving your car with your foot on the brake and gas at the same time.
Both waste energy!
Chart Title
Annual Operating Electrical Cost at Fixed Speed
$19,600 $20,000.00
$18,000.00
$16,800 $15,400 $16,000.00
$14,000 $14,000.00
$13,200 $12,000.00
$11,000 $10,000.00
$8,000.00
$10,500 20HP
$9,000 $7,500 15HP
$6,000.00
$4,000.00
10HP
$2,000.00
$0.00
kWh cost @ .10 cents
kWh cost @ .12 cents
kWh cost @ .14 cents
24
12
4/22/2015
10HP
8,760 Operating Hours (24/7/365)
A 10HP will consume approx. 75,000 kWh
Reduce Speed by 10% (500 gpm to 450 gpm)
Will save approx. 15,000 kWh’s a year
Reduce Speed by 20% (500 to 400 gpm)
Will save approx. 30,000 kWh’s a year
15HP
8,760 Operating Hours (24/7/365)
A 15HP will consume approx. 110,000 kWh
Reduce Speed by 10% Will save approx. 27,000 kWh’s a year
Reduce Speed by 20% Will save approx. 50,000 kWh’s a year
13
4/22/2015
20HP
8,760 Operating Hours (24/7/365)
A 20HP will consume approx. 140,000 kWh
Reduce Speed by 10% Will save approx. 35,000 kWh’s a year
Reduce Speed by 20% Will save approx. 67,000 kWh’s a year
Implications of wasting energy
• Approx 300,000 commercial pools in the US
• Average size commercial pool pump motor is a 10 HP
• Majority of commercial pool pumps run 24/7
• Energy consumed by all the commercial pool pumps is approx 2,250 Megawatts
• A typical Power Plant is 500 Megawatts…
• We need 4.5 Power Plants to run just the commercial pool pumps in the US
•Slowing down the pool pump speeds by 24% reduces the # of power plants required to just 2
Note:
Residential pool pumps offer an even larger opportunity to positively impact energy consumption.
In CA alone, it takes 6 average size power plants to operate the State’s 1.5 million pools!
Information Provided by
National Energy Commission
14
4/22/2015
Pump Speed / Power relationship
%
Speed
(rpm)
Energy
Consumption
100
Reducing Frequency reduces pump speed
90
80
70
60
50
40
30
Filter
20
10
Automatic Flow Control Eco-Flow-C
Eco-Flow-C
Controller
As the filter gets dirty:
Discharge Pressure drops & Eco-Flow-C automatically
increases the pump’s speed to maintain
a constant flow
Supply Voltage
4-20mA signal proportional to pressure
Flow Meter
To Pool
Pressure Sensor
Note:
The pump’s speed must never be adjusted to be below
that required to meet a States mandated turnover
Requirements, i.e., a 6-hour turnover in most States
From Pool
30
15
4/22/2015
Maintaining Constant Flow Constant Flow
Pump Speed
To Pool
FILTER
Pressure
From Pool
31
Questions or Comments?
32
16
4/22/2015
Thank You
33
17