April 2022

APRIL 2022

PROMOTING ENERGY EFFICIENCY

www.eibi.co.uk

In this issue

Building Energy Management Systems CPD Module: Variable Speed Drives Boilers & Burners Compressed Air

Plugging the leaks Industry’s huge compressed air waste

Under examination Controlling student heating costs

Time is right for hydrogen A crucial role in decarbonisation

NEWS � FEATURES � INTERVIEWS � REVIEWS � PRODUCT PROFILES � CPD MODULE � DIRECTORY � JOBS EIBI_0422_001_(T).indd 1

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APRIL 2022

PROMOTING ENERGY EFFICIENCY

www.eibi.co.uk

In this issue

Building Energy Management Systems CPD Module: Variable Speed Drives Boilers & Burners Compressed Air

Plugging the leaks Industry’s huge compressed air waste

Under examination Controlling student heating costs

Time is right for hydrogen A crucial role in decarbonisation

NEWS � FEATURES � INTERVIEWS � REVIEWS � PRODUCT PROFILES � CPD MODULE � DIRECTORY � JOBS EIBI_0422_001_(T).indd 1

06/04/2022 13:53

APRIL 2022

Contents

www.eibi.co.uk

26

11

FEATURES

Jeff House discusses the critical role of hydrogen in protecting UK energy resilience, decarbonising heat and achieving the nation’s net zero ambition (24)

Energy 11 Building Management Systems

With energy prices skyrocketing, environmental pressures intensifying, Christian Engelke discusses whether hydrogen fuel cell technology is finally set to enter the mainstream this year (26)

Jonathan Williams looks at how public and commercial establishments can increase the value and competitiveness of their buildings and infrastructure Contemporary Controls’ BASgatewayLX Modbus to BACnet Gateway (BASGLX-M1) makes Modbus devices appear as individual BACnet devices (12) Jamie Cameron believes that the government may have overlooked the all-important area of smart buildings when it comes to its decarbonisation plans (13) With soaring energy costs and a huge increase in student numbers in the coming years Adrian Barber believes that better control of heating student accommodation is essential (14)

22 Boilers & Burners

Mark Wilkins explains why redundancy is essential for many commercial applications, how it is implemented and why oversizing is unavoidable in these cases

NOx reductions can be achieved with flue gas recirculation technology, says ELCO. Meanwhile Modutherm has introduced a range of floor-standing gas condensing boilers (28)

30

Compressed Air Paul Clark explains how compressed air system health checks and energy audits carried out in an industrial environment can reduce costs and help deliver energy efficiency improvements Vanda Jones discusses the key factors to consider when embarking on a compressed air energy reduction programme – and why now is the time to act (31) Cobalt Energy has relied on BOGE Compressors to supply compressed air systems in the construction of two separate facilities to convert clinical waste into energy (32)

REGULARS 06 News Update

European Union governments are backing a plan to slap an import on certain products from countries with lower environmental standards.

Employment numbers declining in UK energy efficiency sector

09 The Warren Report

What is the best way to get the UK out of the current energy crisis? Perhaps the Government should be looking to past successful policies rather than unproven new technology

17 The Fundamental Series: CPD Learning

It’s estimated that electric motor and drive systems account for over 60 per cent of UK industrial electricity demand. John Pooley looks at how variable speed drives can cut that use

21 Products in Action A community-owned pub installs energy-efficient heating and cooling while a family-owned brewery installs new boiler plant

25 New Products New to the market this month is a networked control system from compressed air specialist BOGE. In addition, Remeha has added a range of air source heat

pumps (ASHPs) to its portfolio of sustainable commercial heating and hot water solutions

33 ESTA Viewpoint

Mervyn Pilley reflects on the Government’s obsession with energy supply and hopes that efficiency becomes a core part of its future energy strategy

34 Talking Heads Businesses will need to go far beyond current legislative measures to meet net zero commitments. Voluntary compliance schemes have a vital role to play, as Mehmet Olgun explains

Follow us, ‘like us’ or visit us online to keep up to date with all the latest energy news and events www.eibi.co.uk APRIL 2022 | ENERGY IN BUILDINGS & INDUSTRY | 03

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Editor’s Opinion

Follow us on @ twitter.com/eibi and twitter.com/eibi_magazine

Sending out a message

When I first came into this job I was told that “the problem with energy efficiency isn’t technology, it’s communication.” I was a little mystified at the time as the conversation took place at a trade show where technology was all around and seen as the key to the future of energy efficiency. But it didn’t take that long to realise that the benefits of energy efficiency weren’t being successfully communicated by the sector, its trade bodies or lobbying groups.

As the supply side grappled with privatisation, the emphasis was on getting the best possible deal.

However, against that background between 2005 and 2015, consumption of gas in the UK really did drop dramatically, by almost one-third (from 55,384 kilotonnes of oil equivalent (ktoe) to 41,707ktoe). As Andrew Warren points out (see page 9) “throughout that decade, Governments ran a series of effective campaigns each designed to minimise energy profligacy. They used building regulations, product standards, cut-price energy saving measures, utilityfunded whole area improvements, social welfare programmes, and industrial incentives. But then in 2015 the Government overnight abandoned its Green Deal.”

Now we are faced with astronomical energy bills,

a net zero target to hit and the requirement to turn our backs on Russian fossil fuels. You’d think that the Government might look towards the quickest win to hit all three. Instead, there seems to be a headlong rush to build more nuclear plant that will not be up and running for many years, if ever. Energy efficiency can provide what we need more quickly and less dangerously.

The emphasis has to be on speed. The Government has used public campaigns in the past aimed at driving a collective response. Posters from the Second World War urged people to cut energy use, and in the 1970s, when the Yom Kippur War drove oil prices skywards, we were urged to “Save It. You Know it Makes Sense.”

The Government should launch public information campaigns on using energy efficiently. I know this will be of no comfort to those struggling to pay their bills but it’s aimed at those fortunate enough to have a comfortable home who are able to turn down the thermostat a degree or two. This would work its way to every workplace in the country. A message on behavioural change could make a huge difference to our energy future.

MANAGING EDITOR

Mark Thrower

The EIBI Team Editorial

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A well-designed system architecture can result in energy savings of up to 30 per cent, as well as lowering maintenance requirements. The right technology allows you to control and monitor all the energy used to heat, cool and light your building and run its equipment. With this real-time information, your operating plant will automatically respond to changes in energy demand.

Jonathan Williams of Siemens Smart Infrastructure Solutions and Services looks at how public and commercial establishments can increase the value and competitiveness of their buildings and infrastructure See page 11 for more details Photo courtesy Siemens Smart Infrastructure Solutions and Services

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News Update

For all the latest news stories visit www.eibi.co.uk

New investigation into debacle of the GHG

The debacle of the aborted English Green Homes Grant scheme has already been the subject of three large official and several unofficial investigations. Each has reached conclusions and recommendations based upon established facts. Even so, the Government is now spending a further £670,000 to fund yet another report into the reasons behind the scheme’s failure.

The official spending watchdog, the National Audit Office (NAO), has seldom issued a more excoriating report than their evisceration of the scheme’s debacle (see EiBI Oct 2021).

The scheme was intended to make 600,000 homes more energy efficient.

It may just have reached 47,500. It was meant to create somewhere between 100,000 and 140,000 jobs, depending upon which Minister was speaking. The NAO concludes it may have sustained 5,600 people in employment.

Its allocated budget was £1.5bn. In the end, it cost the taxpayer £314m, of which just £256m went on actual energy improvements “should all current applications be processed.”

With £50.5m of that going on “programme management and administrative expenses.”

Subsequently, powerful House of Commons committees have held hearings, and in turn, published detailed conclusions upon the failure.

The Environmental Audit Committee called it “a good concept, poorly implemented.” The Public Accounts Committee said it was “a scheme with poor design and troubled implementation,” in the end a “slam dunk failure.”

The NAO Report ended with a clear instruction. “The Department should set out by the end of 2021 how its various home energy efficiency schemes fit with its overall plans for decarbonisation, setting out timescales in a more detailed and longer-term plan. This will help to promote interest in future schemes from consumers and installers.”

In response, the extra £670,000 Business Department study, undertaken by Ipsos Mori, will not be published until the autumn of 2023.

Even so, its commissioning hasn’t stopped Business Departmental spokesmen repeatedly claiming “we have taken the experience of the Green Homes Grant into account when designing new measures.” So quite what will be revealed remains to be seen, albeit in 18 months time.

CARBON BORDER ADJUSTMENT MECHANISM

EU plans environmental standards levy European Union governments are backing a plan that would slap an import levy on iron, steel, cement and aluminium produced in countries with lower environmental standards, as the bloc seeks to shield domestic producers during an ambitious green overhaul.

EU finance ministers have adopted a positive negotiating stance for detailed talks with the supportive European Parliament about the so-called carbon border adjustment mechanism (CBAM).

Proposed by the European Commission last year (see EiBI July 2021), CBAM would impose penalties for bringing into the EU emissions embedded in goods that also include fertilisers as well as electricity.

The levy will be based upon the costs domestic producers already face within the EU carbon market (EU:ETS). It will gradually replace the system of handing out free pollution permits to companies most prone to carbon leakage, or relocating production to countries with laxer climate policies. Under a proposal drafted by France, which holds the EU’s rotating presidency, details on phasing out free allowances will be discussed under a separate law on reforming the Emissions Trading System.

For the past decade, France has called upon Europe to adopt a carbon border charge. The negotiating mandate has handed President Emmanuel Macron a symbolic win before presidential elections this month. Once the

European Parliament agrees on its own position in a parallel process, talks between the two institutions will start about the final shape of the measure.

As part of the planned agreement brokered by France, Governments would back the Commission’s proposal of a transition period of up to three years before full entry into force of the mechanism in January 2026.

Obligations upon importers, including the UK, during that period would be limited to reporting.

Then they would have to buy special certificates at a price linked to the

EU:ETS. The price will be calculated by the Commission as the average of the closing prices at government auctions for each calendar week. European carbon prices soared to record levels earlier this year, before falling after the Russian invasion of Ukraine.

The planned measure is part of a broader package to align the EU economy with stricter emissionsreduction targets for 2030. The EU wants to encourage more climate action from countries outside the bloc, while providing a level playing field for its businesses.

Soaring cost of gas driving householders towards installing heat pumps

In view of the need to cut the UK’s dependence on Russian gas, a third (33 per cent) of British householders say they are more likely to purchase a heat pump, according to new research from the Energy & Climate Intelligence Unit (ECIU).

The research states that Russian aggression and global demand are sending the cost of running a gas boiler higher, with household gas bills up by over £500 between April 2021 and April 2022. They could reach over £1,400 in October this year, according to some industry estimates, which would roughly be another 50 per cent rise, or £450-£500.

The survey also found that half (49 per cent) of all ‘heat pump ready homes’ are interested in getting an electric heat pump – equivalent to about 7m homes.

ECIU analysis found that if all these homes switched from a gas boiler to a heat pump, the need to import gas from Russia would be wiped out completely, two times over.

The ECIU claims that heat pumps break down less and

don’t require as much servicing as a gas boiler, because they have fewer moving parts. Four in ten (38 per cent) of those surveyed said they have had a problem with their gas boiler in the past two years, which jumps to half (51 per cent) for the past five years.

From 2nd April, grants of £5,000 will be available to people switching to an electric heat pump, and the Spring Statement unveiled a cut in VAT on heat pumps, bringing between £1,200-£2,000 off the average price of installation.

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News Update

For all the latest news stories visit www.eibi.co.uk

LOW CARBON ECONOMY JOBS

Employment in energy efficiency declines There are more people employed in energy efficiency than in any other part of the low carbon economy, according to the Office for National Statistics (ONS). But the numbers involved are now declining year-onyear.

In 2020 there were 82,000 full time equivalent jobs in the energy efficient products sector, accounting for 42 per cent of total employees involved in all types of “low carbon” activities.

However, these numbers declined by 6 per cent since 2019. This is attributed by the ONS to reductions in employment in the “energy monitoring, saving and control sectors.”

Statistics for this 82,000 total curiously omitted entirely a sector acknowledged elsewhere by the ONS to fall within its low carbon sector definition, the entire lighting sector.

According to the Lighting Association, there are 12,000 people working in its supply chain and services activities, and 13,000 jobs involved with the “production, import and supply side.”

Including these people within the energy efficiency category would have taken the total sector number up to 107,000. And would mean that well over half of all employees involved with the low-carbon economy could

Graeme Rees takes over as BCIA president

The Building Controls Industry Association (BCIA) has appointed Graeme Rees as its new president. He takes over from Terry Sharp while Paul Wetherfield will take Rees’ place as vice-president.

Rees is currently the UK & Ireland digital energy marketing manager for Schneider Electric and has been involved in the building controls industry for more than 30 years.

After starting his career as a project engineer at Lidworth Ltd he later moved on to Bristol Management Systems. He then spent 19 years at Trend Control Systems where he worked his way up to marketing director.

reasonably be classified as being “energy efficiency” workers.

But the ONS does point out that the sector is responsible for just 29 per cent (£12.1bn) of the low-carbon sector’s overall financial turnover.

The ONS states that this is because “activities within the sector tend to be

Urgent action needed for NHS to reduce carbon emissions, says new report The NHS will not achieve its net zero targets without taking urgent action to reduce carbon emissions, says a new study.

The research from University of Exeter sets out the scale of the challenge the NHS faces and calculates that its carbon footprint,

In Brief

including its wider supply chain, is 31m tonnes of CO2 equivalent, of which 62 per cent can be attributed to its suppliers.

The report states that to achieve the government’s target for the NHS of net zero by 2040, emissions must be reduced 8 per cent each year

more labour intensive, compared with other sectors such as bioenergy, and onshore and offshore wind.” In other words, people involved with energy efficiency tend to be considerably less well paid than those in the more celebrated parts of the low carbon economy. from 2020 to 2036 – a rate far higher than the 1 per cent historical average.

To meet emissions targets, the report calls for the extensive adoption of circular economy practices across the NHS and its suppliers.

Markus Zils, co-author of the report and professor for circular economy and management science at the University of Exeter, said: “NHS leaders have outlined their commitments to making health services more sustainable, but the pace of change has to swiftly accelerate. Our research has outlined that meeting the NHS’s ambitious net zero targets is only possible with the adoption of circular economy practices.”

The report states that stakeholders across government, the NHS and industry must work together to set a new standard for procurement, improve supply chain due diligence and foster innovation to ensure a shift to circular economy practices is sustained.

Lomax to step down as CEO of Kensa Group

Ground source heat pump manufacturer, Kensa Group, has announced that chief executive officer, Simon Lomax, is stepping down due to health reasons. Kensa Contracting MD, Matthew Trewhella, has been appointed as CEO. Lomax will support the leadership transition and serve as a strategic advisor to the Kensa Group Board to provide continuity in client and business development activities.

Under Lomax , Kensa has overseen almost half of all the ground source heat pumps sold in the UK in 2021.

Power from UK roofs hits 3GW in 2021

According to data from MCS (Microgeneration Certification Scheme), solar photovoltaic (PV) panels installed on British homes equated to 3GW of electricity for the UK grid for the first time ever last year.

This represents £20bn, the estimated cost of construction for the Sizewell C nuclear power plant, which will have an energy output of 3.2GW. With installation numbers soaring, the MCS installation database predicts that solar PV will surpass the Suffolk reactor’s output by spring this year.

The data also shows that, in 2021, 61,320 UK properties had solar panels installed – an increase of 71 per cent on the previous year. This takes the total number of ‘sunny roofed’ residential properties to 1m, according to Solar Energy UK.

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News Update

For all the latest news stories visit www.eibi.co.uk

SMEs can’t cut through the net zero jargon

The majority of smaller businesses in the UK don’t understand how common environmental terms such as ‘net zero,’ ‘carbon neutral’ and ‘carbon footprint’ apply to their operations, according to new research commissioned by the British Business Bank.

The survey of 1,000 senior decision makers in smaller businesses found more than half (54 per cent) believe the language, terminology and information around carbon emissions reduction are over-complex. 61 per cent say they would find more information and advice helpful, with over half (51 per cent) wanting to know how to work out the financial implications of reducing their business’ carbon emissions.

The British Business Bank published its ‘Smaller businesses and the transition to net zero’ report in October 2021 and found that SMEs account for around half of total emissions from UK businesses. However, 45 per cent of them believe that a reduction in their carbon emissions will not make a significant difference to the environment, and 72 per cent believe large corporations are responsible for most of the business carbon emissions in the UK.

Solar and battery system at Hants port

The installation of a ground-breaking solar and battery system is underway at Portsmouth International Port, managed by Portsmouth City Council’s in-house energy services team.

The project began in February 2022 and will incorporate roof-mounted solar panels across a number of buildings, a large battery, and solar canopies.

When completed, the power produced by the 2,660 solar panels will contribute around 35 per cent of the site’s power – a significant step in Portsmouth International Port’s ambition to be the UK’s first net zero carbon port. The installation is due to complete in summer 2022.

The project is the first UK port to have solar canopies and a megawatt sized battery installed as part of a renewable installation. When completed, the 1.2MW peak system, will be the largest solar and battery installation to date across the council’s portfolio of renewable generation.

As well as generating carbon-free power, the solar canopies will provide shade for cars waiting to board ferries; allowing them to stay cooler for longer, without having to run their engines.

BUSINESS AND ENERGY SECRETARY

Kwarteng ignoring energy reduction The strategic case for energy efficiency is simply no longer being made publicly by the Cabinet Minister officially in charge of this policy area. There has been almost complete official silence from Kwasi Kwarteng (right), the Business and Energy Secretary, about the potential role that reducing demand in a purposeful fashion can achieve regarding lessening both import and pricing pressures.

Inevitably there are disparaging comparisons being made with the positive and innovative initiatives, emerged and emerging, from not just the European Commission, but practically every other western European government.

His sole comment to date came in a tweet disparaging the Labour Party, when they left office in 2010, for having only ensured that 10 per cent of homes had achieved an energy performance certificate rating of C or above. Had he bothered to check the English Housing Survey covering 2010, para 2.14 would

have told him the correct figure was not 10 per cent but 16.2 per cent.

The continuing absence of any coherent plan to address net zero in buildings via energy efficiency, after the overnight abandonment 13 months ago of the Green Homes Grant scheme, continues to cause genuine commercial despondency within the energy efficiency industry. However, Chancellor Rishi Sunak has agreed to lower temporarily, from 5 to 0 per

cent, the rate of VAT being levied upon a limited range of energy-saving and renewables measures, noticeably insulation installed by registered contractors, photovoltaics and heat pumps. But other established energy conservation measures like glazing or LED lighting are still to be charged at 20 per cent VAT, four times the rate levied on energy consumption.

Separately, Sunak has instructed the new National Infrastructure Bank to make lower rate loans available for “projects that support energy efficiency, including the retrofit of existing buildings.” He has written to the Bank’s CEO John Flint, stressing the “urgent need to improve the energy efficiency of our buildings, in the context of higher energy prices.” In Sunak’s view, doing so would “align with the government focus upon energy security.” This mirrors similar duties placed by the German government upon its equivalent bank, KFW, ever since 2008.

Oldham wins £160,000 funding to investigate using reclaimed heat from disused coal mines Oldham’s former coal mines could soon be heating buildings across the town centre thanks to an innovative scheme to tap into an unused, renewable energy source.

The Oldham Mine Water Heat Network is a pioneering project from Oldham Council which would use heat reclaimed from the floodwater in disused coal mines that sit underneath the town centre.

Initial studies have confirmed the process looks promising for Oldham and the council has now been awarded over £160,000 from the Department for Business, Energy and Industrial Strategy (BEIS) to support the next stage of feasibility works.

Cllr Abdul Jabbar, deputy leader and cabinet member for finance and low carbon, said: “Oldham is one of only a handful of towns in the UK to be developing plans for a mine water heat network.

As the planet continues to suffer and energy bills hit record highs, we must do all we can to find an affordable, eco-friendly solution.

The mine water heat network is an exciting opportunity to use Oldham’s industrial heritage in a

new and sustainable way and supports our Green New Deal commitment – to becoming carbon free as a council by 2025 and as a borough by 2030.”

Mine water gets warmer the deeper it is. Temperatures range from 10 -20°C but can reach 40°C at depths of around 1km. Mine water can be abstracted from boreholes and shafts.

Heat exchangers and heat pumps are used to recover the heat and distribute it via district heating networks to

homes and buildings.

Other projects to boost green energy are also progressing to put Oldham on the map as the greenest borough in Greater Manchester.

The council is also exploring ways for residents and businesses to be able to purchase locally generated renewable energy directly through a ‘local energy market’ which will set its own prices independently of the main energy providers.

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THE WARREN REPORT

04.2022

Ten good reasons for avoiding energy conservation What is the best way to get the UK out of the current energy crisis? Perhaps the Government should be looking to past successful messages rather than unproven new technology

T

he best answer to concerns about gas imports from Russia is simple, tweeted the Financial Times’ chief features writer, Henry Mance: “cut gas use.”

Burning less gas is certainly what we have done before. Between 2005 and 2015, consumption of gas in the UK really did drop dramatically, by almost one-third (from 55,384 kilotonnes of oil equivalent (ktoe) to 41,707ktoe).

Throughout that decade, Governments ran a series of effective campaigns each designed to minimise energy profligacy. They used building regulations, product standards, cutprice energy saving measures, utilityfunded whole area improvements, social welfare programmes, and industrial incentives. But then in 2015 the Government overnight abandoned its Green Deal, despite it having been touted by Conservative ministers as the “biggest revolution of our building stock since 1945.” And since then, gas sales have ceased their precipitous falls. And we import gas from overseas, including from Russia.

Back away from conservation

Given its earlier success, why on earth have politicians backed away from purposefully backing energy conservation? I put this down to ten specific reasons: • why should government subsidise the installation of cost-effective measures?; • isn’t promoting energy saving really akin to sponsoring energy rationing by any other name?;

Andrew Warren is chairman of the British Energy Efficiency Federation

Between 2005 and 2015, consumption of gas in the UK really did drop dramatically, by almost one third

• an Englishman’s home is his castle - we mustn’t interfere. The press can distort, and crucify - remember Daily Mail’s notorious lying campaign about “conservatory taxes”?; • installing energy saving measures can be done ineffectively, sometimes badly enough to damage the entire fabric; • can’t we just mandate putting in even bigger heat pumps, forgetting about the building fabric and hence higher fuel bills?; • energy efficiency policy always involves too many Departments, so is bound to fail (but not between 2005 and 2015); • employment is dispersed, with no strong local bases, and is frequently non-unionised (but still employs more than energy generation); • saving energy is boring. Which politician ever held an opening ceremony for a well-insulated loft?

Real men build power stations; • if we set higher standards for new build, won’t housebuilders stop building? And go out of business? and • if we set higher standards for landlords of existing buildings, won’t the supply of rented/leased out buildings dry up? And go out of business?

The big unspoken issue

And then, the big unspoken issue. That must be why, even when scrapping VAT on some energy-saving options, the VAT rate on several other key energy conservation measures remains at 20 per cent, whereas the VAT rate on energy consumption is at the lowest rate of 5 per cent. And Opposition parties are concentrating on abolishing even that lower rate.

When No. 10 or the Cabinet Office ever consult business leaders to discuss energy policy, those invited are always drawn from the firms that sell energy. Not from those in a position to help customers reduce the size of their energy bills. This has even been true in the run up to the enormous increases in gas bills, due this month and again in October.

Such steep price rises require some

immediate palliative measures.

As I write this, tomorrow Prime Minister Boris Johnson is summoning to Downing Street for a “summit” everyone and his brother involved with nuclear power, including even those hawking a wholly untested smaller prototype. Any solutions on offer are unlikely to be forthcoming on the ground during this entire decade.

But as a distinguished professor of energy pointed out to me, when did any Prime Minister ever contemplate, let alone action, calling together for such a “summit” those involved with delivering practical energy-saving measures? To which question there can only be a negative answer: never.

These are the people who know in detail how we can deliver real change on the ground probably within months, certainly right across the decade.

But only so long as there can be confidence that such measures will definitely remain in place. The last seven years has seen nothing but start/stop interventions, engendering real cynicism among those who could yet return to the vanguard of participants.

During that successful period between 2005 and 2015 that I cited earlier, with gas sales down 32.8 per cent and electricity sales also lower by 15.2 per cent, there were 90 per cent more residential insulation jobs undertaken than today. Even so, the Office for National Statistics still reckon that there are more than five times as many people currently employed in the energy efficiency industry than there are in the nuclear industry. And almost twice as many as are employed in the renewables industry.

Given the worries concerning stagflation, and war, economic commentators perpetually compare today with the problems of the 1970s.

These came about largely because of the Yom Kippur war between Israel and Egypt in 1973, leading to rocketing fuel prices.

Interestingly, what is most remembered from those turbulent times is the slogan promoted vigorously by the then-Conservative Government. It went “Save It. You Know It Makes Sense.” And it still does. 

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Jonathan Williams is branch sales manager at Siemens Smart Infrastructure Solutions and Services

Building Energy Management Systems If the use of a building changes it is possible to quickly adapt the BEMS to the new situation

Flexible architecture Jonathan Williams looks at how public and commercial establishments can increase the value and competitiveness of their buildings and infrastructure

W

e are beginning to see the benefit of data to our everyday decision making. In our homes we have always optimised the use of our central heating. We ensure that the time clock is set appropriately, we search around for the best deal on gas and electricity from our supplier. More recently we have been looking towards technology-based solutions such as Hive, Nest and smart metering, to help with these tasks.

The same is true of our commercial workplace. If a building has a properly designed and installed building energy management system (BEMS), then the granularity of the data and the way in which it is presented can help us make better decisions on our journey to net zero carbon emissions.

A well-designed system architecture can result in energy savings of up to 30 per cent, as well as lowering maintenance requirements. The right technology allows you to control and monitor all the energy used to heat, cool and light your building and run its equipment. With this real-time information, your operating plant will automatically respond to changes in energy demand.

Typical reductions in energy consumption include: • improved control of building systems and services, particularly HVAC; • decreased consumption of air conditioning and heating by scheduling optimum temperatures

and air flows on specific days and at specific times; • room automation and control of lighting and blinds in line with building occupancy and specific requirements; • automatic movement of blinds and shutters to maximise daylight and manage sunlight; • managed energy usage across different areas of your buildings; • real time monitoring of energy performance and proactive adjustment, rather than retrospective catch up; • trend data and energy demand/ consumption dashboards; • load shedding; and • the ability to supply/sell energy back to grid.

As the market moves towards greater system interoperability, modern-day BEMS platforms are designed to manage and integrate other building disciplines.

Importantly, they should be built to interact with most systems on the

A well-designed system architecture can result in energy savings of up to 30 per cent

market, enabling you to incorporate additional subsystems and create a more automated and effective workspace, facilitating proactive, rather than reactive, decision-making.

Unified workflows for multiple building disciplines not only mean optimised training costs, but also substantially reduced infrastructure, such as servers and networks, as well as lower operating costs.

Single point of control

Building energy management technologies that deliver interoperability across your building systems and act as a single point of control, will result in efficiencies in both your mechanical and electrical systems. A fully automated environment and centralised situational awareness will improve occupant wellbeing, optimise productivity and assist you in working smarter.

An optimised room climate has a positive effect on room users, whether it is better motivation, improved concentration or higher performance.

The right software makes achieving the ideal room climate viable by using system-wide intelligent control strategies.

Clear visibility of when and how rooms are being used will save energy by regulating lighting and HVAC to avoid unnecessary costs, particularly during evenings and weekends.

Advanced comprehensive tools and templates can identify and address

issues even before they become problems. With intuitive reports you can better manage your building’s key performance indicators, monitor energy consumption including load profiles and maximum power reporting, plus identify operational and energy performance opportunities. State-of-the-art reporting engines will access trend and event data from the database and provide operational workflows for the delivery of energy, power and maintenance, plus it will support requirements for tenant charging.

If you change the usage of your building or if the layout of the building changes, your BEMS can be quickly adapted to the new situation by the user. Open communication standards offer cost-effective integration capabilities for any building requirement. BEMS software is highly scalable and can be employed within individual buildings, as well as across multiple site operations enabling users to view their whole estate in real time from a single location. Access to the BEMS data can now be available remotely via mobile devices offering greater and faster response to building performance issues from anywhere, and at any time.

Data centres represent a particular challenge for energy efficiency across the globe. For German IT service provider, DVZ, who host and process data, Siemens introduced an energy data management system with 140 measurement and metering points for electricity, cooling, ventilation and heating with dashboards for KPI tracking. Siemens’ Desigo CC platform delivers load management for electricity and cooling, cold aisle containment with direct server cooling, demand-dependent control and optimisation of ventilation systems. The outcome has been energy transparency and improved sustainability with increased supply reliability in the compound cooling system. DVZ’s power usage effectiveness has improved by approximately 17 per cent, total power consumption has reduced by 21 per cent and load peak decreased by 17 per cent.

Whatever the size of a building or plant, its purpose or application, an integrated BEMS will enable an automation and control solution that meets your individual requirements.

With openness and flexibility at its core you can reduce the cost of energy consumption and your CO2 emissions through significant energy savings, while offering a healthier room climate and higher user satisfaction. 

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Building Energy Management Systems Gateway offers a meeting of Modbus and BACnet minds Modern building energy management systems are designed to maximise operating efficiency of energypowered devices such as heating, ventilation and air conditioning.

Modbus remains a popular communications protocol in building automation, particularly for boiler and burner control, variable speed drives, and metering applications.

However, most BEMS now use BACnet open communication protocol for its flexibility and adaptability. But these Modbus devices do not offer BACnet compliance.

Contemporary Controls’ BASgatewayLX Modbus to BACnet Gateway (BASGLX-M1) makes Modbus devices appear as individual BACnet devices, providing gateway functionality between Modbus

serial (ASCII, RTU) or TCP devices and BACnet/IP. The BASgatewayLX has one 10/100 Mbps Modbus TCP and BACnet/IP Ethernet port and an opto-isolated Modbus EIA-485 serial port for Modbus RTU or Modbus

ASCII devices. This helps in cases where no BACnet support is available from the boiler manufacturer. Even if a replacement communication card for BACnet is available from the manufacturer, the BASgateway

provides a more cost-effective option.

Up to 100 Modbus serial devices represented by up to 1000 polled points can share the Modbus EIA-485 port on the BASgatewayLX. BACnet COV notification is supported on 200 points (100 Analog and 100 Binary points). The virtual routing feature in the BASgatewayLX allows each connected Modbus device to appear as an individual BACnet compliant device for easy identification. Modbus data points such as setpoint, air and water temperatures and modulation from Modbus Serial or Modbus TCP devices can be mapped to BACnet objects.

Integrating a Modbus device to BACnet requires a device profile for each Modbus device. Contemporary Controls maintains a library of common device profiles available for download. If the device profile is not available, Contemporary Controls will provide it upon request free of charge.

These rugged metal enclosed devices are available with DIN-rail or panel mounting and powered from a 24 VAC/VDC source.

Building Energy Management Systems

Jamie Cameron is director of digital solutions at Johnson Controls UK&I

Implementing the right smart technology in the right ways can transform how building management businesses operate

The positive outcome of being smart Jamie Cameron believes that the government may have overlooked the all-important area of smart buildings when it comes to its decarbonisation plans

T

he race to tackle our sustainability problem remains as prevalent as ever.

Governments and businesses alike have set out detailed plans to move towards net zero. In 2021, the UK government published their comprehensive net zero strategy, alongside detailed plans to cut emissions in the 30m buildings across the UK. However, when prioritising reducing carbon emissions and reaching net-zero, the strategy is missing one important tool – smart technology, and specifically smart buildings.

Businesses across the UK are implementing smart solutions into their buildings, just not at the pace required to see real change. Our recent research shows that just 34 per cent of UK buildings are fitted with smart technology. Yet, when asked how important smart technology is to performing their role, almost every respondent (99 per cent) saw the value of smart technologies. While smart technology is clearly a priority, businesses aren’t truly embracing the benefits it could have for their goals and looking at these figures, the disconnect between awareness and action becomes clear.

When the pandemic disrupted the world of work, the focus for smart tech turned to health and

safety. Businesses across the country implemented point solutions such as thermal cameras, contactless access controls, air purification systems and remote management into buildings to make it safe for employees to return to work. But as sustainability and efficiency conversations continue to take precedence a new era is on the horizon. What may seem like a daunting goal, in fact, isn’t. Businesses can meet net zero targets while remaining on track with employee safety and comfort. But it lies in holistically bringing smart solutions together and ceasing to rely on siloed approaches.

If we get the technology right in our buildings now, we can transform the way we use them in the years to come. But first we need to move away from solutions and concentrate on

our desired outcomes. This means changing the way we operate: our buildings need to deliver ROIs and achieve net zero carbon and energy efficiency targets, all while ensuring occupant comfort and safety.

Innovation through AI

Using a platform with built-in AI is where innovation can also happen.

These technologies enable integration and enhanced intelligence across a building or estate – improving the building operation for its occupants, from modelling building and equipment performance to factoring building system data and external input like weather or traffic. In turn, this allows for machine learning to optimise spaces in a building to cut energy spend and waste.

For example, energy efficiency

savings can be made from automatically reducing the use of electricity in low-footfall areas, by monitoring sensors around a building and making real-time decisions based on the insights. This means that occupants are always comfortable, but the building isn’t wasting resources.

The challenge is that we need to manage the combination of operating tech, bringing together multiple data sources and different systems to drive value. Digital twins, for example, can turn the physical world into computable objects. Computable objects provide a consistent way for software to manage and represent entities from the physical world.

These can then be used to predict the future state of physical objects, and to simulate or test future processes.

If a product is having any issues, or is nearing the end of its lifecycle, a digital twin can notify and send out an engineer with the right part to fix it first time. The building can remain energy efficient while bringing down costs to the business.

Smart solutions can also integrate all technologies found in a building across the fire, security, controls, HVAC, and occupancy systems, increasing overall efficiency and therefore reducing energy consumption. This is inherently advantageous, as businesses can lower energy consumption in their buildings to achieve net-zero goals but also save on energy costs.

This has never been more important with the ongoing energy crisis, which will soon affect business nationwide. Numerous revolutionary technologies such as digital twins, the internet of things, machine learning, artificial intelligence and automation mean that smart buildings can operate autonomously with little human interference. These building management systems can successfully optimise buildings without the manual help of humans, and only require intervention when they are notified.

Implementing the right smart technology in the right ways can transform how building management businesses operate, delivering the experiences occupants need and want, and supporting their own business financially and operationally.

The outcomes of smart buildings are multi-faceted: improving system efficiency while powering impactful sustainability, working towards the all-important net zero goals.

It’s clear now that sustainability and energy efficiency are finally coming to the forefront, and it is evident that reviewing and investing in smart technology is the place to start.  APRIL 2022 | EIBI | 13

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Building Energy Management Systems

Adrian Barber is marketing manager at Prefect Controls

The student energy cost crisis

Control at the point of use is the only way for organisations to supervise consumption

With soaring energy costs and a huge increase in student numbers in the coming years Adrian Barber believes that better control of student accommodation heating is essential

T

he tone of an email I received recently was almost incredulous. The director of a newly opened student accommodation facility had just installed electric panel heaters in around 200 rooms. But he was finding that the occupants were adjusting the room thermostats to 35°C and then leaving them at this setting constantly. To cool rooms that were too warm, windows were being opened.

This, unfortunately, is not uncommon. With the energy cost crisis now starting to bite reducing the use of, and therefore, the spend on energy has swiftly risen to the top of many agendas.

Factors affecting energy costs are many including: government regulation; weather forecasts; storage of fossil fuels; demand; and transport. But in recent weeks all our minds have been sharply focussed by global markets and supply. Stable energy imports are, perhaps, no longer as reliable as we thought.

Many forecasters are predicting interruption to supply and high prices for the foreseeable future.

Whichever method of energy generation is delivered, whether from gas, renewables or nuclear, costs are rising and scarcity is becoming a very real possibility. Therefore, control at the point of use is the only way for organisations to supervise consumption and keep a handle on costs for themselves.

The current unpredicted energy crisis will hopefully be relatively

short term. But growth forecasts for some sectors project very predictable long-term demand for energy. Purpose built student accommodation (PBSA) is experiencing a relentless expansion.

Just considering population growth, latest reports1 suggest a further 40,000 new university places will be required by 2035. When participation rates are considered, a staggering 350,000 additional places will need to be made available in the same timescale.

There are currently 115,000 new beds in the PBSA development pipeline. In 2021 alone there was a net increase of just over 21,000 new beds entering the market.

High-quality, serviced rooms

The ease of moving into high-quality, fully serviced rooms is very attractive when going to university. This is what has fuelled the growth in this sector to almost 700,000 purpose-built beds.

A population of this size has a similar energy demand to that of a medium sized UK city. With decarbonisation target deadlines looming, accommodation providers need to minimise energy waste, in terms of both costs and carbon.

Managing energy use in student accommodation can pose a real conundrum for energy managers, particularly when an ‘all-inclusive’ deal is the business model. The occupants expect comfortable rooms but have no responsibility for directly footing the bill for the heat they use, while energy managers need to curb

Occupants expect comfortable rooms but have no direct responsibility for footing the heat bill

unnecessary energy use but maintain comfortable rooms and happy occupants.

For the sender of the email mentioned earlier, the consideration, when converting his property should have extended beyond ‘which is the most cost-effective source of heat?’ to ‘how can that heat be controlled most effectively?’

Control systems designed specifically for student accommodation provide managers with far greater influence on consumption than relying on integrated electric heater controls in each room.

The minimum requirement should be programmable thermostats that only allow boost heating when asked for, reverting to the setback temperature after a pre-determined period. This avoids the ‘set it and forget it’ at 35°C. The system should also sense empty rooms/open windows and reduce heat input accordingly. This type of thermostat,

known as Local Control, is robust, built for non-domestic environments, and is tamper-proof. It requires a dedicated secure handset to programme each room individually.

For larger properties a centrally controlled building energy management system (BeMS) is a preferred option. A system that performs the same basic tasks as Local Control units but is operated via an internet portal. This provides energy managers with access to every room, remotely – a real benefit during the pandemic. The room node is more sophisticated than the Local Control type and can also monitor environmental conditions such as humidity, light, CO2, and decibel levels - automatically alerting managers to unusual readings.

Stepping out of the bedroom and into the bathroom, even greater savings can be made when the BeMS controls water heating. With this comes the potential for leak detection and the monitoring of complete water system temperatures.

BeMS don’t just provide economic benefits. Convenience, fault finding in hardware, the archive of data, and monitoring of best safety practices, are also present. For example, the data collected from water systems provides evidence that the criteria used in water safety plans have been adhered to for the prevention of legionella. When the kitchen is also included within the BeMS jurisdiction – monitoring of cooking appliances means the power supply is cut before ignition or flash points are reached should temperatures on the cooking surface reach dangerous levels or if the kitchen is left unattended by a distracted student.

But ultimately, in the current climate, efficient use of energy is the focus of concerns. The installation of a Building energy Management System can result in quite staggering savings - up to 40 per cent has been cited. The return on investment is usually quoted to be under five years, but with the instability in the energy market and rising costs that length of time could be slashed.

Now is the time to make energy go further by not using it unnecessarily, after all, the cheapest energy is the energy we don’t use.

Reference

1) Cushman Wakefield UK Student Accommodation report 2020/21

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SERIES 19 / Module 09

Variable Speed Drives

Variable speed drives

By Eur Ing John Pooley, BSc, CEng, CMC, FIE, FIC, John Pooley Consultancy Ltd

A

For details on how to obtain your Energy Institute CPD Certificate, see ENTRY FORM and details on page 20

ccording to International Energy Agency, electric motor systems use around half of global electricity. It is also estimated that across the UK and EU some 8bn motors are in use. For the UK it is estimated that electric motor and drive systems account for over 60 per cent of UK industrial electricity demand. In practice, a large part of this is accounted for by fans, pumps and compressors – both refrigeration and air. This makes addressing energy use in motors and drives an important topic to address.

In simple terms an electric motor is a machine used to convert electrical power into mechanical power. Electric motors are highly efficient at this conversion. Larger motors can be over 96 per cent efficient with smaller motors typically being above 80 per cent.

While a motor can be high efficiency this does not mean that the complete motor-driven system is efficient. The complete system needs to be critically evaluated. This should always start by having an understanding of the load – the job of work that is to be undertaken. From the energy saving point of view, the question ‘does this work need to be done at all?’ is a good place to start. Having decided a job of work needs to be done the next step is to do it as efficiently as possible.

Some loads will be fixed duty – the

solution here is to have an efficient, fixed-speed drive system. However, where the system load can be varied or modulated the scope for energy saving is present.

Energy savings up to 40%

Using variable speed drives (VSDs) to control motor systems can typically save 15-40 per cent of energy used in applications where the load on the system is variable. The use of VSDs is particularly effective in fan and pump applications where they might be used to replace mechanical methods of output regulation. For example, a 20 per cent reduction in fan speed can lead to a 50 per cent reduction in energy use.

CEMEP (European Committee of Manufacturers of Electrical Machines and Power Electronics) reports that global electrical energy consumption could be reduced by 8 per cent if VSDs were used in every suitable application. They also note that 75 per cent of VSDs are used on fans, pumps and compressors.

The speed of an AC induction motor is determined by the number of poles in the motor and the frequency of the AC supply – fixed in the UK at 50Hz–

so in practice the motor speed is determined by the number of poles.

It should be noted that the actual speed of a loaded motor is less than its nominal speed as a result of slip.

For example, a fully loaded’ four-pole motor at 50Hz might run at 1,425rpm, not the nominal speed of 1,500rpm.

The motor needs to be coupled to the load. Where the speed ratio is 1:1 this can be a direct coupling. Where the speed of the load is a ratio of the motor speed a common solution is the pulley and belt drive.

In industrial applications gearboxes are also used – particularly where very low speeds are required. The efficiency of gearboxes can range from 85-90 per cent for a worm and gear gearbox to around 98 per cent for a helical gear box. Pulleys and gearboxes provide a stepped, fixed speed change.

There are a number of ‘mechanical’ options to provide a variable speed output: • variable pitch drive – the pitch diameter of one or both pulleys in a pulley and belt drive is made adjustable; • hydraulic hydrostatic drive – uses a positive displacement hydraulic

The speed of an AC induction motor is determined by the number of poles Number of Poles Nominal Speed

2

4

6

8

10

3,000

1,500

1,000

750

600

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Variable Speed Drives pump and motor to provide the variable speed output; • hydrodynamic drive – two impellors coupled together with hydraulic fluid; and • hydro-viscous drive – has a number of discs on the input and output shafts with a thin film of oil between them.

There are also other mechanical ‘capacity’ control options for specific applications such as inlet guide vanes for fans to provide a variable air volume. While devices like these control the capacity of the fan, in many systems dampers are used to ‘throttle’ the air volume – or valves for fluid flow.

A common example of this is reducing the speed of a fan by 20 per cent reduces the power required by 50 per cent.

When looking at torque it is important that the ‘starting torque’ of an application is understood as this may have an impact on motor size and selection. For example, a motor may appear to be oversized, but that size of motor is required to meet the starting torque of the specific application.

Need to run below 50Hz

Options for variable speed

When comparing variable speed drives to other capacity control methods the analogy of driving a car is worth considering. Using a throttle valve or damper is like driving a car with the accelerator in a fixed full power position and then using the brake to control speed.

The options for variable speed motors are: • DC motors – this was a traditional solution for variable speed applications but often with longer term maintenance issues; • variable speed motors (AC) – often a solution for smaller applications.

One example is the ECM or electronically commutated motor.

This is a good option for fan coil units, condensing units etc. Another is the switched reluctance motor found in air compressors; and • AC motors & variable speed drives (VSDs) – these are the most common application for energy saving and HVAC applications.

The electronic variable speed drive is also known as the inverter or variable frequency drive (VFD). A VSD works by using power electronics to change the frequency of the power supply to the motor. Frequency being one of the two factors determining motor speed (the other being the number of poles).

As an example, if we had a four-pole motor running at mains frequency (50Hz) its nominal speed would be 1,500 rpm. If we wanted it to run and 600 rpm the supply would need to be ‘converted’ to a 30Hz supply. See below The process for achieving a variable frequency supply is to convert a 50Hz AC supply to a direct current (DC) and then by a process of pulse width modulation (PWM) synthesise an AC supply with a different, controllable frequency.

The VSD is a proven, reliable technology for controlling the

Typical applications for the three main types of motor load LOAD TYPE

APPLICATIONS

Constant Power

Centre Winders Machine tools Paper machines Traction control equipment

Constant Torque

Agitators Compressors Conveyors Crushers Mixers Positive displacement pumps Stirrers

Variable torque

Centrifugal pumps Fans

speed of an AC motor. To deploy the concept of the VSD we need to look at the types of motor load and the benefits using a VSD might offer. It is important when looking at loads to understand torque. Torque is the rotating force produced by a motor – typically measured in Newton metres (Nm). Torque combined with speed becomes the motor power.

load the torque output is constant and the power is proportional to speed (see Fig. 2). This means that a 50 per cent reduction in speed delivers a 50 per cent reduction in power. Examples include conveyors, air compressors & crushers • variable (quadratic) torque – the most common load type (see Fig. 3) – torque is quadratically (square law) associated with speed while power is cubically proportional to speed (cube law). Examples include fans & pumps. However, in a pump system where a static lift is required the cube law does not apply to that component of the load.

Three common types of load

There are three common types of motor load: • constant power – here the power requirement is fixed and torque is inversely proportional to speed (see Fig. 1). Examples include machine tools and centre winders. With these applications changing speed does not save power. VSDs for constant power loads are used for process control, not energy saving.

• constant torque – with this type of

For a variable torque load where Q = flow rate; P = power and N =speed Q1/Q2 = N1/N2 and P1/P2 = (N1/N2)3

Speed of a four-pole motor at different frequencies Frequency (Hz) Nominal Speed (rpm)

60

50

40

30

20

10

1,800

1,500

1,200

900

600

300

While VSDs are very efficient there are some losses. Typical efficiency ratings are in the range of 92-99 per cent. However, this means that if a VSD is driving a motor at its nominal speed the overall power consumption will be greater than if the motor was running at that speed without the VSD. In simple terms, for sustained energy saving the VSD needs to run below 50Hz. It should also be noted that VSDs can also be used to ‘overspeed’ motors and by running them above 50Hz energy use will be increased.

For a VSD to deliver energy savings the speed needs to be controlled.

Manual control is normally used only in process applications. For effective VSD deployment there needs to be an automatic control loop. The type of sensor, location and protocol will depend on what is being controlled.

For example, a VSD might be used to vary the air volume of an extract ventilation system for an underground car park. The control parameter here would be carbon monoxide.

The protocol will be to control the ventilation rate to limit the build-up of carbon monoxide (CO) from car exhausts.

For this to function correctly it is important to position the sensor(s) in the right place(s) – and set the correct CO control levels. It is then critical that the system is fully commissioned – i.e., checking that it works as intended.

Energy surveys have documented instances of VSDs installed but either not commissioned or having the controls ‘tampered’ with. Issues like this can be addressed with regular recommissioning.

In HVAC applications VSDs are normally installed for their energy savings potential. However, in some cases they can be installed as ‘commissioning’ tools for ‘fixed’ duty installations. The argument to support this application is that typically electric motors run at only about 70 per cent of their full load and in many fixed rate applications the flow (water or air) is throttled to meet the design requirement. By using a VSD a precise speed to match the

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Variable Speed Drives duty can then be selected during the commissioning process – optimising the power use. It also provides scope for recommissioning should the duty of the system change later.

Often new equipment is supplied with a matched VSD. However, there are still many opportunities for retrofitting VSDs to existing fixedspeed installations. In these situations, it is always good practice to seek advice from the VSD supplier when selecting the variable speed drive.

In addition to matching the drive to the load there may be issues with the existing motor to be addressed.

The cooling for a typical AC motor is delivered by a shaft-mounted fan that rotates at the same speed as the motor. This can mean at lower speeds the cooling effect is reduced (this problem is overcome in DC motors by having a separate motor to drive the cooling fan). Combined with this reduced effect cooling the VSD may also increase the heating effect on the motor. This can potentially lead to an early failure of the motor. Insulation breakdown and overheating issues are more likely with older motors.

As a result, in some cases, it may be appropriate to replace the motor when fitting a VSD.

• dynamic response – comparable to DC drives, but with lower costs.

However, there are some disadvantages to VSDs including: • while they can have a wide rangeability they cannot operate the same as a control valve at low flow or near zero flow conditions – in these applications a control valve may still be required even if a VSD is used; and • for some specialist applications the speed of response of VSDs may be slower than that of a control valve.

Fig. 1 The power requirement is fixed and torque is inversely proportional to speed

VSDs are not plug and play

Fig. 2 Torque output is constant and power is proportional to speed

Harmonic distortion

Another aspect to be considered is that of harmonics. Harmonic distortion is a form of electrical ‘pollution’ that can cause problems if it is above certain limits. These problems can include cables overheating, motors becoming noisy with torque oscillations leading to mechanical resonance and vibration. Harmonic currents are created by non-linear loads connected to the power distribution system.

Common non-linear loads include VSDs, welding supplies and uninterruptible power supplies. In VSDs the type of rectifier used has a significant impact. Budget VSDs often have 6-pulse rectifiers. Harmonic performance can be improved by having 12, 18 or 24 pulse rectifiers – however, this is at a cost. A 24-pulse unit might be double the cost of a 6-pulse unit. Other mitigation options are IGBT rectifiers, large chokes or active filters. Expert advice is recommended in this area to avoid future problems.

Following Brexit, the UK is still following the ecodesign requirements for motors and drives. Prior to 1 July 2021 it was permitted to use an IE2 (efficiency) motor fitted with a VSD in place of the required IE3 motor.

However, with effect from 1 July 2021, this is no longer acceptable.

Fig. 3 Variable torque load is the most common. Examples include fans and pumps

The regulation also stipulates the efficiency of variable speed drives.

Variable speed drives have two levels of efficiency (IE1 and IE2). The regulation now requires all drives in scope to reach the IE2 level. This means that the power losses of VSDs for motors with a rated output power equal to or above 0.12 kW and equal to or below 1,000 kW shall not exceed the maximum power losses corresponding to IE2 standards.

As well as energy saving in many

applications, VSDs can also offer the following benefits: • programable starting, stopping and braking - which can reduce system stresses and prolong life as well as providing the ability for more frequent stops and starts; • improved power factor – AC motors typically have a power factor of less than 0.85 and this decreases with lower loadings in some cases below 0.5 – a VSD can bring the power factor closer to unity; and

We tend to think of electronics as plug & play, fit and forget – but this is not true for variable speed drives.

A number of important issues need to be considered. One of the most significant is the cooling the VSD. Power electronics generate heat and if that heat is retained in a closed enclosure it can lead to overheating of the drive with subsequent failure.

Typical problems here might include air vents becoming blocked in a dusty atmosphere; drives being installed in closed cabinets and overheating.

The Energy Technology List (ETL) is a government list of energy efficient plant and machinery. For a product to be listed, it must meet the ETL’s energy-saving criteria - typically set at the top 25 per cent of products in the market. In the past, equipment on the ETL qualified for Enhanced Capital Allowances (ECA) - a tax benefit however, ECAs ended in April 2020.

The ETL still remains a good source of product related information for energy savings.

The ETL covers two categories of VSD products: • variable speed drives for line operated AC motors; and • variable speed drives for converterfed motors. https://etl.beis.gov.uk/products/ motors-drives/variable-speed-drives When correctly installed and used on fans and pumps with variable duty, VSDs can provide significant energy savings by matching the input power to the duty required. VSDs are proven technology and if installed correctly will provide years of service. However, in retrofit applications it is always advised to involve specialists in the selection and installation of the drive. 

FURTHER READING 1) 2) 3)

CTV048 Motors and drives technology overview guide – Carbon Trust Technical guide No. 6 - Guide to harmonics with AC drives ABB Drives The Control Techniques Drives & Controls Handbook – The Institution of Engineering & Technology ISBN 9781849190138

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SERIES 19 / Module 02 09

Refrigeration Variable Speed Drives

ENTRY ENTRYFORM FORM

“Energy in Buildings and Industry and the Energy Institute are delighted to have teamed up to bring you this Continuing Professional Development initiative” MARK THROWER Managing Editor

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20 24 | ENERGY IN BUILDINGS & INDUSTRY | SEPTEMBER MARCH 20202020

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Products in Action

New heating, cooling for 18th century pub

Family owned brewery opts for new steam boiler at Manchester site

The New Inn Pub in Warwickshire, a community-owned pub dating back to 1750, needed a new approach to heating and cooling to create a welcoming and pleasant environment for its customers.

PANASONIC Etherea air conditioning units with nanoe X were recommended as the ideal solution by installer and village resident Oli Thorndale of Thorndale Heating & Cooling.

When the villagers took over the property, it was very run down and needed a complete renovation throughout, including the heating system which was an old LPG gas-fired boiler.

With the price of gas going up and its less than environmentally friendly credentials, gas was considered an expensive and inefficient fuel.

As this was 2021 and during the pandemic, COVID was very much at the forefront of everyone’s minds. With many villagers feeling vulnerable, the steering committee wanted to provide confidence in the pub, as well as creating a safer

Manchester-based Seven Bro7hers Brewing is one of the UK’s largest family run breweries, As well as the brothers who own the brewery, there are also four sisters who run a gin company, so they have vast experience in all aspects of the brewing industry.

When the decision came to invest in a new steam boiler, they came across CFB BOILERS LTD, which like Seven Bro7hers, is a familyrun business. This appealed to the brothers together with the fact that CFB Boilers have 126 years’ experience in the steam boiler industry and that their boilers were manufactured at their purpose-built factory.

After a competitive quote the Seven Bro7hers company purchased a 20HP 4VT steam boiler which had an additional 20 per cent steam capacity compared to the existing steam boiler on site.

The project was on a tight time scale, as the boiler installation needed to take place within days of the brewing vessels arriving and being installed.

and healthier environment. It was at this point that the steering committee learnt about the benefits of Panasonic’s nanoe X; a technology to improve air hygiene by preventing transmission of airborne pathogens.

Installation of wall-mounted Etherea air conditioner with nanoe X built-in as standard now provides not only energyefficient heating and cooling but can also inhibit the growth of certain bacteria and viruses.

Boilers & Burners

Mark Wilkins is technologies and training director at Vaillant

Contrary to myths, a system where the boilers are cascaded does not waste energy

Why oversizing is essential

Mark Wilkins explains why redundancy is essential for many commercial applications, how it is implemented and why oversizing is unavoidable in these cases

O

versizing a heating system accidentally should never happen.

However, implementing a redundancy contingency in certain plant rooms is not only wise, but the deliberate over-sizing by adding additional back-up boilers in cascade can offer a range of benefits.

By controlling and designing such systems in the right way, heating systems can be used efficiently, alternating the heat between boilers so that they are effectively being used less, therefore improving the lifespan of the product while providing essential and comfort conditions.

There is a wide range of nondomestic buildings where the provision of heat is critical to an organisation’s operations. To ensure heat security, redundancy is built into the heating system using ‘spare’ boilers. Without this back up to deliver heating and hot water, lives could be put at risk, businesses could incur significant losses, and occupants could suffer disruption to important aspects of their daily lives.

Protected services such as hospitals and nursing homes need hot water and heating to keep vulnerable

patients safe, comfortable, and ensure maximum hygiene on the premises.

Thermal comfort is also essential in educational establishments and childcare settings, as set out in the requirements of Building Bulletin (BB) 101. Adherence to the guidelines not only contributes to occupants’ physical health, but also the ability of both staff and pupils to concentrate. Loss of heating and hot water could lead to building closures and disruptions to their education. The Health and Safety Executive also places constraints on employers to provide basic comfort and care to their employees, so there is a legal framework in all workspaces, even in office environments.

Heat is not only needed to keep people safe and comfortable. Many industries require heat and hot water for manufacturing processes. Without these, production would grind to a halt, resulting in significant losses to businesses. In museums, humidity levels and temperatures must be kept constant to preserve valuable artefacts.

If their condition is not maintained, this could result in damage to irreplaceable objects which have historical and cultural significance to a country.

Installing a system with cascaded boilers is advantageous in that it operates at its maximum capacity during the highest heat demand. At the same time, it can guarantee heat security if a failure occurs or during essential maintenance.

Meeting heating demand

For example, in a nursing home with a 600kW heating demand, six or seven Vaillant ecoTEC plus 120kW boilers could be set up as a cascade. This ensures that the heating demand can be met with five units fired up, with one or two spare units as back-up.

Should a fault occur, for instance if one boiler doesn’t fire up as needed, the Vaillant VRC 700 controller, which can be used in a cascade set up with

The units in a cascade are not idle, they are operational under normal circumstances

up to seven boilers, would recognise this and simply use one of the others to continue delivering heating and hot water.

The backup units in a cascade system do not sit idle, they are fully operational under normal circumstances. This is because the operator can programme the controls so that all units, including the spare ones, work on a rotational basis and manage changeovers. There are two important advantages to this set-up. By spreading the load, the risk of breakdowns in all units can be reduced, and their life can be prolonged. Using the back-up equipment regularly also ensures that they would operate when needed.

There are other circumstances where the inclusion of back-up boilers could result in even greater oversizing.

For example, in a commercial building with a heat demand of say, 280kW, while a 280kW ecoCRAFT may be able to support the heat demand, for increased system flexibility and heat security, it’s often more effective to install three 120kW boilers, oversizing by a total of 80kW. In this case, the system would be oversized by 30 per cent. But if usage is rotated equally between the three units, at any given time two of the boilers would be covering more than 90 per cent of the heat demand, so a product such as a Vaillant commercial boiler could operate well beyond the 15-year industry-expected lifespan.

Contrary to myths, a system where the boilers are cascaded does not waste energy. They are controlled so that only some of them are fired up to provide the amount of heat required at any particular time. Vaillant’s VRC 700 can automatically manage this process for cascade installations with up to seven Vaillant boilers, and integrate with any BMS via additional accessories. If there are more than seven Vaillant units, they can integrate directly with the BMS via additional accessories, so that building operators can manage their heating in the most energy-efficient way.

Plant sizing shouldn’t be exceeded, and system diversity factors should be used correctly. However, plant rooms must be capable of all the challenges it is designed for. Having redundancy in a heating system not only prepares a building in the event of breakdowns but can also extend the lifetime of the system when designed and controlled wisely. 

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Boilers & Burners

Jeff House is head of external affairs at Baxi

Hydrogen-ready boilers could be mandated from 2026

The time is ripe for hydrogen Jeff House discusses the critical role of hydrogen in protecting UK energy resilience, decarbonising heat and achieving the nation’s net zero ambition

A

t the time of writing, the UK government is preparing to unveil a new energy strategy to improve Britain’s energy independence and protect households and businesses from volatile global energy markets.

Renewables such as wind and solar power are rightly expected to be part of the new strategy to free the UK from dependence on imported gas and oil. However, the speeding up the introduction of hydrogen – thereby diversifying gas supply – could play a critical role in protecting national energy security while supporting our 2050 net zero ambition.

And we’re not alone. Increasing the profile of green hydrogen is a key focus of the European Commission’s REPowerEU plan to provide the bloc with energy independence before 2030.

It proposes producing an additional 15m tonnes of green hydrogen on top of its original 2030 target of 5.6m tonnes, together with a boost in deployment of wind and solar power.

We have long espoused the view that, along with electrification and heat networks, hydrogen has an exciting part to play in the future energy mix – particularly in poorly insulated, harder to treat buildings where the technically and financially viable options can be restricted. Here are some of the reasons.

Hydrogen boilers produce zero

carbon emissions at the point of use as the main by-product of burning hydrogen is water. This will help businesses and organisations to achieve their net-zero emissions target.

Businesses and homes will be able to use heating and hot water in the same way as today, without major changes to their heating systems. This makes it a low disruption option.

Hydrogen can be produced domestically and used effectively to store energy over longer periods of time, providing intersessional flexibility and offsetting the intermittent nature of renewable generation. As such, it has the ability to improve energy resilience and security.

Hydrogen into the mix

Is the infrastructure in place? It is expected that the first step will be to introduce a blend of up to 20 per cent hydrogen into the natural gas mix, which could save six million tonnes of carbon dioxide a year nationally – equivalent to taking 2.5m combustion engine cars off the road (Source: HyDeploy).

Energy Networks Association has confirmed that all five of Britain’s gas network companies are ready to start blending hydrogen from next year.

This will also mean that Britain’s gasfired power plants will be able to use blended hydrogen to generate cleaner electricity.

Is the blend safe? As a leader in hydrogen boiler technology, we have been working closely with government on a number of projects to trial hydrogen for heat.

20 per cent hydrogen blends have been successfully demonstrated using our natural gas boilers at the HyDeploy project at Keele University, proving that blending hydrogen with natural gas is feasible and safe – and a greener alternative to the gas we use now.

Phase 2 of the HyDeploy project is now live in Gateshead, supplying a blend of up to 20 per cent hydrogen to over 600 existing homes.

According to this work on the HyDeploy project and the Gas Safe Bulletin TB159, current domestic natural gas boilers and other appliances are compatible with hydrogen blends of up to 20 per cent.

In other words, no changes to heating products, guidance or measures are needed.

We would like more ambitious targets introduced for hydrogen deployment

Although, for customer peace of mind of a future-ready installation, we have secured independent certification that our Remeha Quinta Ace and Gas 320/620 Ace condensing boiler ranges are 20 per cent hydrogen blend compatible.

When will we switch to hydrogen boilers? Demand for pure hydrogen boilers will be dictated by the gas distribution networks as their deployment will coincide with local area network conversions and larger scale pilot projects.

The next phase will be the introduction of ‘Hydrogen Ready’ boilers – which could be mandated from 2026 according to current plans – which we see as the bridging solution to the energy transition.

These boilers initially use natural gas but can be easily converted to hydrogen at the point of a local network switch over. As of today, the standards and certification framework to enable a product to be classified as ‘Hydrogen Ready’ are not yet in place so watch this space.

The final evolution is 100 per cent hydrogen boilers, appliances that are designed specifically to operate on hydrogen at the point of installation.

We are now demonstrating a 100 per cent hydrogen boiler as part of the government’s Hy4Heat programme in Low Thornley near Gateshead.

Our hydrogen boiler produces no greenhouse gases at the point of use.

Next year the first approved trial of a hydrogen village involving around 300 occupied homes will take place in Fife, Scotland. Following on from this, a hydrogen village is planned for 2025, with OFGEM set to give the go ahead to successful bidders shortly. A further commitment in the UK Hydrogen Strategy and Heat & Buildings Strategy is a hydrogen town scale deployment that could be supported with a hydrogen grid by 2030.

But while progress with hydrogen is moving in the right direction, the supply infrastructure needs to accelerate to support diversification of national energy supply.

The UK government’s current ambition is for 5GW of low carbon hydrogen production capacity by 2030. We would like more ambitious targets introduced for hydrogen deployment to support our climate goals and a ramping up of domestic production to drive greater national energy independence.

On every level – commercial, sustainable and political – it would seem that the time is now ripe for hydrogen. 

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New Products

Networked control system 'promises to cut energy consumption' The latest networked control system from compressed air specialist BOGE promises to reduce energy consumption and improve maintenance efficiency in manufacturing operations.

BOGE Airtelligence Provis 3 is an intelligent management solution which takes remote control, monitoring and auditing of compressed air systems to a new level. Unlike previous networked control products, Provis 3 is limitless in its scope and scale. It has been developed for larger and more complex plants with multiple compressors and equipment.

Importantly, it can securely integrate and upgrade new and old components from different manufacturers.

Provis maximises energy efficiency by intelligently and proactively matching fluctuations in compressed air demand with flow from the optimum combination of compressors and other components.

Further energy-saving benefits result from Provis energy auditing, reporting, costing and performance testing functions, whose clear

Three-strong range of heat pumps joins heating, hot water solutions

insights enhance budgeting, decision-making and planning.

In addition, Provis enables monitoring of equipment condition and activity, so maintenance interventions are timed optimally to minimise costs and downtime.

Authorised users can access intuitively displayed information and check, control or adjust equipment via the inbuilt Provis 3 display, or remotely on their PCs, tablets or smartphones.

REMEHA has added a range of air source heat pumps (ASHPs) to its portfolio of sustainable commercial heating and hot water solutions.

The E-HP heat pump range is available in three outputs with individual heat capacities of 44kW, 88kW and 168kW and cascade options that dovetail with current commercial customer heat demands. The 44kW unit is eligible for capital grants under the government’s Boiler Upgrade Scheme (BUS) to support the installation of heat pumps in domestic and smaller non-domestic buildings. The BUS opened for grant applications from 1 April 2022.

The monobloc design is a self-contained heat generator, extracting renewable heat from the atmosphere and amplifying it using refrigerant compression. Specifically manufactured for northern Europe climate conditions, the Remeha E-HP AW can deliver a high supply temperature of up to 65°C and operate down to ambient temperatures of -20°C, providing a sustainable solution for all UK buildings.

Quiet, smart and energy efficient, the new Remeha E-HP AW heat pumps can be seamlessly integrated with other Remeha products and heat sources to provide sustainable heating and hot water solutions for new build and retrofit applications.

Boilers & Burners

Christian Engelke is technical director at Viessmann

The right funding packages have to be in place for fuel cell microCHPs to be viable for most homeowners

What future for fuel cells?

With energy prices skyrocketing, environmental pressures intensifying, Christian Engelke discusses whether hydrogen fuel cell technology is set to enter the mainstream this year

H

ydrogen fuel cell systems that generate heat and power in domestic and commercial buildings are

not new.

While fuel cells are a successful and proven technology, it’s one that many installers and consumers still consider to be too big, costly, or too far a leap into the future. However, that could now be changing.

Fuel cell micro-CHPs suit a diverse range of properties and circumstances, from high-end new builds and renovations to more regular boiler replacements where homeowners are looking for an environmentally friendly solution, but where heat pumps aren’t feasible.

They work by converting natural gas to hydrogen, which is then used to generate both power and heat through an electrochemical reaction known as cold combustion. In an exceptionally clean and efficient process, hydrogen is used as both a fuel source and energy store, while the carbon-producing combustion that takes place in conventional condensing boilers doesn’t happen, saving around two tonnes of CO2 per year. Viessmann’s Vitovalor’s fuel cell generates as much power as 30m2 of photovoltaic cells, but, unlike solar panels, it does it day and night, in all weathers.

As energy prices continue to spiral, the appeal of such efficiency is growing. For an average property, the combined gas and electricity savings now equate to around £1,500-£2,000 per year, up from £900 a year ago, based on Ofgem data, and this is set to increase further. Maintenance costs, too, are minimal; the Vitovalor fuel cell requires servicing only every five years.

In a fuel cell micro-CHP gas is converted to hydrogen which is used to generate both power and heat

However, the up-front cost of the technology can be a barrier. PACE funding is only available until mid 2022 to mitigate this issue, but that is no longer the case, and, when the government’s Feed-in Tariff (FiT) was replaced by the Smart Export Guarantee (SEG) in 2019, the financial case for fuel cells weakened. While a homeowner can still sell excess electricity to their energy supplier through the SEG, and while its value will grow as fuel prices continue to rise, the current best SEG rate offered is around 20 times lower than FiT payments were initially.

Viability for home owner

So, with large and growing energybill savings on one side but a sizeable up-front cost and low SEG payments on the other, is fuel cell technology financially viable for the average property owner today?

The short answer is yes - provided the right funding packages are in place. With units costing slightly more than ASHPs, financial support is critical to put this technology within reach of most people.

The good news is that grants available via the Ogfem-run Energy Company Obligation (ECO) scheme for low income, fuel-poor and vulnerable households are set to dramatically increase in size for many homeowners,

making new fuel cell systems cheap – or even free – to install in many cases.

Launched in 2013, ECO runs in three-to-four-year cycles. During the third cycle, which is now concluding, customers were entitled to claim several thousand pounds towards their purchase costs, based on their anticipated fuel savings. However, if ECO4 is approved to begin in April 2022, funding will be allocated according to the difference a new system will make to the Energy Performance Certificate (EPC) rating of a property. As a fuel cell micro-CHP can thrust a building up several EPC bands in one go, that equates to a very substantial level of ECO funding – potentially enough to cover the entire cost.

This is especially important to landlords, as the Minimum Energy Performance of Buildings (No. 2) Bill currently working its way through parliament proposes that all rental properties should have a minimum EPC-rating of C by 2025.

Viessmann is working with energy conservation and renewables specialist Happy Energy Solutions Ltd to simplify access to grants for customers and installers. Happy Energy liaises with EDF to organise funding on behalf of installers, so that installers can concentrate on winning the business and fitting the technology. Happy Energy recently coordinated a package of funding for a couple in Hackney, east London, that covered the entire cost of a new Vitovalor fuel cell boiler (and solar panels). This reduced their energy bills by around 40 per cent, slashed their carbon emissions and moved their three-bedroom, end-of-terrace, Edwardian home from EPC rating D up to A. They’re now exporting electricity to the grid and receiving payments from their energy company.

But what about higher-income households that are not eligible for ECO funding? How does the financial case for a Vitovalor fuel cell mCHP stack up for them?

If electricity prices continue to rise as predicted, then homeowners could save in the region of £800900 per year based on an average of 4,500kWh/pa. In this scenario, the cost to generate a kWh of electricity for self-consumption is half the cost of purchasing from the grid.

As the technology becomes more commonplace, we could well see a momentum building that carries it into the mainstream during the next year, especially given the recent Spring Statement that micro combined heat and power products are included in the zero VAT technologies from April 1st 2022 to 31st March 2027. 

26 | ENERGY IN BUILDINGS & INDUSTRY | APRIL 2022

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Boilers & Burners Flue gas recirculation innovations cut NOx emissions

ELCO Burners has developed a wide range of products that feature FGR (Flue Gas Recirculation) Technology.

This system has been specifically designed to reduce NOx emissions to less than 30mg/kWh, even when burners are matched to boilers with a low thermal load, or on high flue temperature applications, such as oil thermal heaters.

ELCO has recently completed an impressive project in Seoul, South Korea, which included the installation of four ELCO Burners at the country’s

largest hospital complex. Three of the new units were Ultra Low NOx Gas Burners with FGR technology – each

delivering a powerful output of 16MW with NOx emissions less than 30mg/ kWh, while contributing to a combined

system output of 80MW. These now provide highly efficient and low NOx heating and hot water services to the hospital building.

For monobloc burners, FGR consists of delivering a mixture of air and flue gas to the combustion head of the burner.

This results in a significant reduction in NOx emissions from the unit.

To achieve these reductions, a new pipeline is installed to connect the flue gas outlet of the boiler to the burner fan inlet. This is sized to minimise any pressure drop and provide an adequate rate of flue gas to deliver reduced NOx emissions. Generally, the extraction point is at the base of the flue pipe, where the pressure is close to zero, resulting in a suction being generated in the burner intake box, which is a function of the fan curve and the air damper position. 

Vegetarian food producer looks to drive down its carbon intensity Protium, the UK‐based green hydrogen energy services company, and its consortium partner, Petrofac, are to explore the deployment of green hydrogen technology with meat-free pioneer Quorn.

Quorn’s production facility, Belasis, in Billingham continues to expand its production capacity to support the company’s growth. Protium and Petrofac will assess how the introduction of dual-fuel boilers (combusting both hydrogen and natural gas blend) can meet their expanding production capacity.

Located close to Quorn’s Belasis production facility, Protium and Petrofac will explore the feasibility of supplying green hydrogen via a pipeline as part of Protium’s green hydrogen project in Teesside.

Following a string of recent updates demonstrating Protium’s project velocity and expanding CAPEX pipeline, this project represents a wider strategic move from Protium who recently announced a planned hydrogen hub, in Teesside, located one mile from Belasis. Here, the team will be utilising Wilton Engineering’s site to deploy up to 40MW of electrolysis, which will produce over nine tonnes of green hydrogen per day. Initially, Protium would look to displace part of

Quorn’s natural gas demand with green hydrogen which could save as much as 13,200 tonnes of CO₂ emissions per year. This would be equivalent to removing 7,600 cars from the road.

Mark C Taylor, chief engineering officer at Quorn, said: “Quorn Foods is committed to being net-positive by 2030. We are also aiming for net-zero emissions within our operations by the same date.

“To achieve this, we are considering all options to drive down the carbon intensity of our process heat and electricity consumption. The transformational opportunity which green hydrogen potentially presents is one we are taking very seriously.”

The project could serve as a blueprint for other manufacturing companies looking to decarbonise their manufacturing processes, not only in the vegan protein space but across the broader food and beverage manufacturing sector.

According to a 2021 report by the Waste & Resources Action Programme (WRAP), the UK food and beverage industry contributes to 35 per cent of the UK’s total GHG emissions, meaning the industry plays an integral role in tackling climate change and achieving net zero. 

Schools and offices the targets for new range of floor-standing boilers Modutherm has introduced the Genesis FS ULTRA range of floorstanding gas condensing boilers.

Ideally suited to larger commercial heating applications, including schools, offices, retail outlets, hotels or heat networks, the flagship FS ULTRA is available in eight models with outputs ranging from 334kW to 2,666kW from a single unit, or cascade installations up to 16 boilers.

All models can operate at a ΔT up to 30ºC and a 6 bar pressure, while offering turndown ratios up to 30:1.

The boiler range also delivers excellent durability and efficiencies up to 109 per cent, thanks to a NHEXT stainless steel heat exchanger, while an integral BLUEJET premix burner provides high flame retention and stability. NOx emissions are also kept below 36mg/ kWh (Class 6), easily exceeding the

requirements for the best BREEAM NOx rating to provide two credits.

To further improve efficiencies, the FS ULTRA range has a low water content design, which facilitates rapid heat up times, as well as reduced fuel consumption. The design also keeps unit weights and dimensions to a minimum, making them perfect for roof top plant room installation and for applications where space is at a premium.

Ian Bradley, managing director of Modutherm, said: “Commercial boilers are still essential products for many of the UK’s buildings, especially in larger properties, or when retrofitting old and inefficient units. In such cases, opting for a highly efficient and low emission boiler, such as the FS ULTRA, is a great choice and can dramatically improve efficiencies and running costs.” 

28 | ENERGY IN BUILDINGS & INDUSTRY | APRIL 2022

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Compressed Air

Paul Clark is business line manager - CTS Sales at Atlas Copco Compressors

Time for a full health check Paul Clark explains how compressed air system health checks and energy audits carried out in an industrial environment can reduce costs and help deliver energy efficiency improvements

E

ven the most conservative analyses estimate that compressed air systems account for 10 per cent of all energy used in global industry, and of that, between 10 – 30 per cent is wasted on leaks. This wastage is expensive; even a 3mm leak could cost around £2,000 a year, with a loss equivalent to 16 tonnes of CO₂ emission. So, any optimisation of compressed air systems – no matter how small – impacts performance and efficiency significantly, lowering fuel bills and reducing carbon footprints.

The simple and most effective means of achieving optimisation is to carry out a health check and energy audit. These assessments can be performed quickly and accurately, and in some cases at no cost, and with zero disruption to the users’ production operations. Just one important aspect of these checks is identifying and eliminating leaks.

Leaks can be caused by many issues including corrosion, poor pipe connections and bad seals. And without investigation, these problems can add up to a significant amount of wasted energy over time, resulting in higher bills.

There is a variety of techniques that can be employed to locate, log, quantify and rectify air leaks. Initial steps involve little or no technology. In fact, some leaks can be found simply by listening and their location can be identified by the elementary technique of applying a soapy water solution to potential leak points such as joints, flanges, and valves, with bubbling indicating the source.

A more precise approach employs advanced technology. The use of ultrasonic leak detection equipment, which operates without interrupting plant production, reaches system areas that are hard to access, and locates all air leaks.

Leaks clearly marked

Once inspection has been completed, leaks can be marked on-site with weatherproof tags, along with a supporting written report that can provide more details on leak locations, photographic evidence of holes, leak severity in litres/minute, energy costs, positions, and costs to repair.

It is often not possible to know that leaks exist unless surveys are carried out

With the technology in place to provide fast, accurate and cost-effective leak detection, compressor technology specialists have developed three levels of health checks and energy audits for compressed air installation. Some of these services are offered freeof-charge, while others require an upfront investment which is quickly recouped through energy efficiency improvements, and the subsequent cost savings they bring: • Level 1 – free visual inspection and energy potential calculations (EPC). A visual assessment covers information such as compressor room environment, determining any air quality issues, and a visual inspection of all compressed air equipment on site, including appropriate capacity, ISO compliance, unproductive running, and pressure levels.

EPC calculations can also be carried out, focussing on the power usage of the compressors, load v. unload hours, and average leak assessment.

• Level 2 - Energy assessment and recommendations through data logging. While EPC delivers an estimation of potential energy savings, this next level service provides a realworld assessment based upon the findings of data logging equipment fitted to each compressor. The data

Even modern systems are likely to have some leakage after six months logging devices record and then map the energy consumed over a full week period, showing the actual running hours and calculated air usage.

Based on this data, engineer specialists can then calculate a realistic energy savings potential, Many air audit services offered by compressor suppliers are free of charge

make simulations, and provide recommendations to achieve optimal energy efficiency. This service can also be free of charge.

• Level 3 - Full audit to ISO 11011:2013 standard. The full audit service provides a premium assessment of a range of parameters, such as flow testing, air leak detection, air quality testing, measurement and analysis of pressure and dewpoint throughout the wider system, from compressor room to production processes. Included in the audit are reporting and discussions of the most suitable methods to reduce energy costs and CO₂ emissions.

Even the most modern compressed air system is likely to have some level of leakage within six months of installation. Manufacturing facilities are often harsh operational environments. Over time, leaks can occur due to factors such as human error, sub-standard welding or pipe connections and damaged valves and seals. Often, it is not possible to know that leaks exist unless they are looked for, which is why leak detection surveys are crucial.

Easy health checks

It is wrong to assume that health checks and energy audits will disrupt production lines. The initial steps, such as a health check, couldn’t be easier and involve a visual assessment that can be conducted in as little as ten minutes, with no downtime whatsoever. Even more sophisticated data logging and ultrasonic testing, and the fitting of flow meters, can be performed in a completely unobtrusive manner.

Many of the air audit services offered by compressor equipment suppliers are free of charge. Even when there is an upfront cost the efficiency savings discovered always amount to more than the initial outlay.

There is little doubt that compressed air health checks, energy audits and leak detection can have a transformative effect on business operations. There are experts on hand to help tailor the various levels of service to operators’ needs, resulting in a unique set of findings that will relate to the specific requirements of an organisation. 

30 | ENERGY IN BUILDINGS & INDUSTRY | APRIL 2022

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Compressed Air

Vanda Jones is executive director at the Briitsh Compressed Air Society

Energy going up in thin air

efficiency. Efficiency in the generation of compressed air is one aspect but targeting avoidable waste in the system is even more important.

Even when off-load, compressors can consume up to 70 per cent of their full load power, so units should be switched off overnight where there is no demand for air and running hours optimised to reduce costs.

Reducing air leaks can have the biggest impact on overall system efficiency. Leak rates in industrial systems are typically between 20 and 40 per cent, meaning the compressor must work harder, and therefore consume more energy, to compensate for the pressure loss. A tiny leak of just 3mm can cost more than £700 a year in wasted energy, but an out-of-hours survey can identify leaks easily.

Vanda Jones discusses the key factors to consider when embarking on a compressed air energy reduction programme – and why now is the time to act

O

ften referred to as the fourth utility, industry relies on compressed air to keep plants performing profitably and efficiently.

However, it is not a free resource.

Generating compressed air can be very energy intensive, representing between 5-30 per cent plus of a site’s total electricity bill.

Coupled with this significant overhead, poor practices and housekeeping can also contribute to unnecessary wastage. In fact, according to a report entitled ‘Compressed Air Systems in the European Union’, when looking at the most important energy saving techniques available to compressed air users, ‘the energy savings amount to 32.9 per cent, achievable over a 15-year period.’1 Using figures from the recent UK Energy-related products policy study, conducted by ICF in May 2021, BCAS calculated the combined energy usage for the mid-point of all industrial compressor technologies over their lifetime at 11.71TWh.2 Based on the current UK average non-domestic electrical unit cost of £0.1249/kWh3, the figures are substantial - equating to £1.475bn being spent by UK companies to generate the compressed air their businesses rely on.

Add to this the fact that over 30 per cent of this energy is being wasted through inefficient practices – equivalent to £485.43m in wasted electricity spend - and there is much that businesses can do to cut this figure significantly.

Yet, compressed air energy consumption is often overlooked, when, as we have already learnt, the potential for wastage is substantial and represents a considerable overhead, not to mention carbon footprint that could be reduced.

Take full system approach

A compressed air system is just that; a system, and every element of it impacts on its energy consumption.

Therefore, when exploring the potential savings that could be realised, it is important to take a full, system approach – from generation to air treatment to distribution and finally, the point of use.

Huge amount of wasted heat

UK companies spend £1.475bn generating compressed air - over 30 per cent is wasted

Many actions will require elements of maintenance or equipment/system upgrade, but the human element should not be overlooked. Substantial efficiency improvements can be made by implementing new processes and encouraging staff to use compressed air more efficiently and safely. For example, not allowing benches or equipment to be cleaned down with compressed air will save a significant amount of air being vented into the atmosphere.

BCAS members can advise on the best equipment and system for a particular application. This could include incorporating fixed and variable-speed drives or a combination of both as well as efficient downstream equipment.

For example, if a site installs the most efficient compressor available, but connects it to a system with a 30 per cent leak rate, then all the benefits are lost. Operators should aim to improve the overall system

Taskforce urges users to aim for 10% cut

The British Compressed Air Society (BCAS) has launched its 10 per cent Taskforce initiative to encourage compressed air users to cut their energy consumption from compressed air by up to 10 per cent.

BCAS is calling for UK businesses to take simple steps, many of which can be achieved at little or no cost.

Working together the industry could save over £147.5m in wasted electricity costs.

As much as 95 per cent of the energy consumed by a compressor is converted to heat and, unless captured, will be wasted to the atmosphere. Many manufacturers offer heat recovery systems, which can often be retrofitted.

Treating air to remove dirt, water and oil is necessary but can use a lot of energy. The process is likely to only need a proportion of the compressed air to be treated to a very high purity. In these cases, excellent savings are achievable by treating all the generated air to the minimum acceptable level and improving the purity (quality) to the desired level at the usage point.

Low-cost, regular maintenance will help retain low leak rates and reliability of equipment. Operators should consider a policy that specifies that energy efficient options are purchased when replacing all equipment – whether it is a basic drain valve through to the actual compressor unit itself.

Finally, the manufacturer’s genuine spare parts should be used, instead of cheaper alternatives. These can enable significant savings in excess of 25 per cent. 

References

1) Compressed Air Systems in the European Union. Energy, Emissions, Savings Potential and Policy Actions. Peter Radgen and Edgar Blaustein 2) Data obtained from the UK Energy-related products policy study. Conducted for the Department for Business, Energy, & Industrial Strategy by ICF Consulting Services Ltd 3) https://www.gov.uk/government/ statistical-data-sets/gas-and-electricityprices-in-the-non-domestic-sector APRIL 2022 | ENERGY IN BUILDINGS & INDUSTRY | 31

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Compressed Air

Waste to energy with compressed air Cobalt Energy has relied on BOGE Compressors to supply compressed air systems in the construction of two separate facilities to convert clinical waste into energy

W

hen consultancy Cobalt Energy won a contract to build a new energyfrom-waste plant, it knew that a reliable compressed air system would play a central role in its success.

The company specialises in thermal renewable, solar and energy-storage technologies in the UK. In 2019, as an engineering, procurement and construction management (EPCM) contractor, it began constructing Haylers End Energy Recovery Plant in Malvern, for its client Waste Energy Power Partners. The plant began operating in 2020.

Haylers End – which was previously a derelict waste-incineration facility – uses a reciprocating grate system to process 8,000 tonnes/year of clinical waste, received from the National Health Service (NHS) and private medical companies. The plant scavenges power using a modern waste heat-recovery boiler. This raises steam that can generate electricity and provide hot water to clean the clinical-waste receptacles. In full operation, it operates self-sufficiently in terms of electricity consumption.

Any excess is fed into the distribution network.

To operate successfully, the facility needs a reliable supply of compressed air. This is necessary for the flue-gas clean-up system, and to operate components such as valves in ancillary systems. The flue-gas clean-up system can work with lower-quality compressed air – but the ancillaries needs air certified as Class 2 according to ISO 85731:2010. During the commissioning phase, Cobalt Energy produced a specification for a suitable compressed-air system and put it out to tender.

“We invited several companies to Malvern to outline their systems,” says Wade Pritchard, senior project manager at Cobalt Energy.

BOGE won the tender and in compliance with strict planning regulations, BOGE designed, supplied, installed and commissioned an integrated compressed-air system

efficient aluminium heat exchanger.

This reduces performance losses in the refrigeration cycle while using less refrigerant than comparable models.

The systems are completed with DAZ absorption dryers – which have active carbon towers – and Beko 13 auto drains.

“The installation work carried out

by BOGE went very smoothly,” says Pritchard. “It makes my job much easier when contractors are reliable and professional – and abide by all health and safety regulations.”

Pritchard was suitably impressed by BOGE when a similar contract came in. Cobalt had been asked to build a larger energy-from-clinical-waste facility – this time in Stoke on Trent, Staffordshire. Pritchard asked BOGE to supply the compressed air system directly, rather than through tender.

Ease of maintenance

Two 30kW screw compressors are operating at the Stoke clinical waste processing site

that met Cobalt’s specifications. It included duty and stand-by screw compressors, refrigerant dryers, absorption dryers and auto drains.

Planning restrictions

One project complication was the presence of planning restrictions.

These specified that Haylers End had to be re-built in the image of the original site, which added significant complications. For instance, the air compressors had to be fitted in the basement. Getting air to and from them – and keeping them cool – required a complex arrangement.

However, BOGE project manager Neil Gibson managed to navigate these issues – such as by helping to design

an appropriate ventilation route.

In addition, the space available for the compressed-air system was limited. This was overcome, however, by the bespoke, designed layout of the equipment for system flow, to suit the tight space, thanks to the relatively small footprint of BOGE’s compressors. For the duty and stand-by systems, it recommended its 15.14-kw C 20 F/S screw compressors. These, like all models in the C series, are designed to fit into small spaces. They are also reliable and easy to maintain – because they use a minimal number of pipes and connections. They were combined with BOGE’s DS26-2 refrigerant dryers, which feature an energy-

The Stoke facility will be capable of processing 16,000 tonnes/year of clinical waste, and works on the same principles as the Malvern plant. For the new project, BOGE recommended larger duty and stand-by systems than those in Malvern. It proposed a pair of its 30kW S 40 screw compressors, which are designed for energy efficiency, reliability and ease of maintenance. These operate with two DS 40-2 refrigerant dryers which have energy-efficient aluminium heat exchangers and two DAZ 36-2 adsorption dryers with active carbon towers. As with the Malvern installation, the systems also feature a pair of BEKO 13 auto drains.

“The Stoke project was more straightforward than Malvern,” says Pritchard. “There’s more room, and it’s all on one level. In terms of footprint, it is probably 50 per cent larger than Malvern – but the compactness of BOGE’s machines has still been highly beneficial.”

The strong working relationship built up between the two companies has also developed further. At one point, complications in the planning of the facility forced Cobalt to put its order with BOGE on hold for several months.

“Neil bailed us out of that one,” says Pritchard. “Fortunately, it worked out – and we still received the compressors in plenty of time.”

The Haylers End plant is now up and running – while the Stoke facility is on the verge of completion. Cobalt Energy plans to approach BOGE directly for compressed-air systems for future construction projects. 

32 | EIBI | APRIL 2022

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ESTA VIEWPOINT For further information on ESTA visit www.estaenergy.org.uk

then energy efficiency does indeed become a supply side issue. The energy strategy arising from the market chaos and sanctions has been delayed so I can only hope that when it finally does arrive, with or without nuclear power stations, it will contain energy efficiency. The lack of willingness of the chancellor to fund the nuclear investment coupled with the limited support offered to energy users, especially business users, in the spring statement worries me and reinforces my big concern that the Government is expecting far too much from the private sector in financing the various strategies published last year. £90bn of private sector in the current situation seems to be incredibly optimistic.

When will the first fuel come first?

Mervyn Pilley reflects on the Government’s obsession with energy supply and hopes that efficiency becomes a core part of its forthcoming energy strategy

I

am coming up to the end of my first three years at ESTA and I could never have imagined what an extraordinary three years they have been. Long, drawn-out negotiations to get a Brexit agreement over the line greeted my arrival. Then we had an election where a different result could have potentially turned energy policy on its head yet produced a Government that steadfastly does not seem to want to engage with lobbying activity no matter how well reasoned. Then along came a pandemic that decimated the face-toface activity on which ESTA had forged its reputation, and now a horrendous war. Add in turmoil in the energy markets where all of the focus has been on supply and its security together with an unexpected change to the certifying body for our major training programme, and I feel as though I have been on one long roller coaster ride. The good news is that while I have never enjoyed roller coaster rides for real, I love what I do and remain totally convinced that an effective membership organisation can really contribute to solving many of the problems facing us.

The irony for me is that I was brought into ESTA to effect change and that, despite the circumstances outside of my control, I have continued to do.

Not all of the projects have moved as quickly as I would have liked but our

40th anniversary is proving to be a spur to push forward with ambitious plans for this year. Ironically, as I have looked to return us to that face-toface meeting and networking activity, I have discovered a knock-on effect of the rapid energy prices increases.

All venues have put their prices up considerably and as they scrabble to recover lost revenue from the pandemic availability of sensibly priced meeting places around the UK has dropped.

However, in addition to a return to trade show activity this year with an energy efficiency zone at the Installer/ Elemental trade show at the NEC between the 21st and 23rd June 2022 and a return to the Smart Buildings show at ExCel in October, we are also planning a number of road show type events where members can showcase their wares to existing and potential customers. We even have some ambition to return to the days when we had our own exhibition but that will not happen for a year or two.

One big frustration remains the fact that the Government’s focus is still very much on supply – where is it coming from and how secure are our existing supplies with very few giving any attention at all to demand side. My view remains that if you agree with the view in the IEA report that energy efficiency should be regarded as the first fuel

Mervyn Pilley is executive director of ESTA (Energy Services and Technology Association)

One big frustration remains that Government focus is still very much on the supply side

Roll out of EV chargers

Following on from my colleague George Barnes’ article in last month’s edition I also remain concerned about how effective the Government’s plans are to roll out EV chargers. Time is short and local authorities are cash strapped so it is unlikely that they on their own can deliver the number of charging points needed especially in rural areas and the north of England. This is really part of the levelling up strategy although it is not always linked to that.

On the ESTA front we are refreshing our energy efficiency in buildings research group run jointly with BESA. While we have good expertise in the group already the turmoil caused by the pandemic has meant we have lost some members. We are open to nonmember experts having a part to play in the group as thought leadership is an important aim.

You also will not be too surprised that a large amount of my focus is currently on recruiting new members from sectors that would not have been traditional markets for us – facilities management companies, building services engineering companies, M&E divisions, retrofit professionals, architects and designers. These are all areas where commercial energy efficiency is especially important.

Irrespective of the apparent lack of interest from so many people on the importance of energy efficiency we will continue to shout the message aloud.  • If any reader is interested in joining ESTA, please get in touch at mervyn@estaenergy.org.uk. Join us to drive the energy efficiency movement forward.

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TALKING HEADS Mehmet Olgun is head of net zero compliance with EQUANS

Mehmet Olgun

I

n 2019, the UK became the first major economy in the world to pass laws to end its contribution to global warming by 2050 – setting a target to bring all greenhouse gas emissions to net zero by that date. This went beyond the target set in 2008 to reduce carbon emissions by 80 per cent below 1990 levels. To help achieve this target, the government has introduced a raft of mandatory compliance schemes that require businesses to measure, report and reduce their greenhouse gas emissions.

For organisations, ensuring full compliance with these schemes – which include Streamlined Energy & Carbon Reporting (SECR), The Energy Savings Opportunity Scheme (ESOS), and UK Emissions Trading Scheme (UK ETS) – can be a complex process that demands considerable time and resources. Given the administrative burden of mandatory compliance, many organisations regard compliance with any additional voluntary standards as beyond their capabilities and resources. But adopting internationally recognised standards for energy management or carbon footprinting – such as ISO 50001 and ISO 14001 – not only simplifies and supports compliance with mandatory legislation, it also unlocks greater environmental, financial and reputational benefits for the business.

It’s also increasingly clear that mandatory schemes alone will not deliver the government’s new net zero targets. The latest Intergovernmental Panel on Climate Change (IPCC) report suggests that current efforts to decarbonise will not be sufficient to keep global temperature rises within 1.5°C above pre-industrial levels. In light of these findings, governments and businesses will need to go beyond current legislative measures to meet their net zero commitments.

Tightening up of regulations

The government has already announced a tightening up of schemes like ESOS, which are set to become more stringent to better support the drive towards net zero. At the recent UN Climate Change Conference of the Parties (COP26), Chancellor Rishi Sunak announced that all large, listed firms would have to introduce not just climate-related risk disclosures, but

Olgun: 'it's important for organisations to avoid duplication of effort in complying with different schemes'

ESOS, and will find it significantly easier to achieve their CCA carbon reductions There are a number of other worthwhile voluntary schemes that businesses can opt to comply with, including ISO 14064 for validating and verifying greenhouse gas emissions, and PAS 2050 for quantifying the carbon footprint of specific products or services. There are also schemes, such as Global Real Estate Sustainability Benchmark (GRESB), Global Reporting Initiative (GRI) and Carbon Disclosure Project (CDP) which may be appropriate for different businesses, depending on their size, sector and location.

Compliance confusion

Voluntary schemes can cut carbon

Businesses will need to go far beyond current legislative measures to meet net zero commitments.

Voluntary compliance schemes have a vital role to play, as Mehmet Olgun explains comprehensive net zero strategies.

A new taskforce is to be created to develop a robust compliance standard for these strategies. It’s a strong signal that regulatory pressures are set to increase on large businesses, meaning now is the time to get ahead by implementing effective net zero strategies to tackle carbon emissions effectively and sustainably.

Adopting the processes and behaviours required to comply with voluntary accreditations, such as ISO 50001, establishes best practice and creates the baseline of data needed to fulfil many regulatory obligations. It also sets the groundwork for developing a net zero carbon roadmap, which every business will need as regulations tighten up and the global deadline for reaching net zero approaches.

ISO 50001 is the internationally recognised standard for Energy Management Systems (EnMS). It gives businesses the most robust and effective framework for improving energy efficiency over the longterm. By complying with ISO 50001, businesses will automatically meet the reporting and auditing requirements for mandatory regulations, including

It can be confusing for businesses to select the right schemes for their net zero ambitions

The plethora of voluntary compliance schemes available can be confusing. It can be difficult for businesses to select the right schemes or combination of schemes to fulfil their specific net zero ambitions in the most efficient and cost-effective way. It’s important to avoid duplication of effort in complying with different schemes, and to ensure that the data-gathering, operational processes and behavioural changes required for any scheme are appropriate to the size and nature of the business.

That’s why it’s helpful to get expert advice at the outset, to identify the right voluntary accreditation schemes for each business – ones that will deliver lasting operational, cost and efficiency benefits, while simplifying compliance with all relevant mandatory schemes.

EQUANS has developed Certify, a service that combines compliance and carbon-reduction expertise into one simple partnership arrangement. Our experts help to support compliance with both voluntary accreditations and mandatory regulations, while easing administrative burdens and improving efficiencies. The aim is to give businesses the peace of mind that they are tackling the challenges of decarbonisation and compliance in the optimum way, while maximising opportunities to improve energy and operational efficiency, reduce costs and achieve challenging net zero targets. 

34 | ENERGY IN BUILDINGS & INDUSTRY | APRIL 2022

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EIBI_0422_035 Directory_EiBI Directory nov 10 2 31/03/2022 13:20 Page 35

DIRECTORY CONTACTS

To advertise in this section contact classified sales on Tel: 01889 577222 Email: classified@eibi.co.uk www.eibi.co.uk

Air Conditioning

Compressed Air, Industrial Gases & Vacuum

Energy Monitoring & Targeting

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Meters - Water, Oil, Gas & Heating

Lighting Controls

Meters - Water, Oil, Gas & Heating

TURNKEYaM&T Meter and monitoring any utility. In house designed hardware and software.

SME’s, City Wide Projects, Large Organisations. Pulse, Modbus, Mbus. www.energymeteringtechnology.com enquiries@energymeteringtechnology.com Tel: 01628 664056

Cooling

Heating & Hot Water

Control & Automation

Meters

Controls & Inverters Heat Networks

METERING DOCTORS

Temperature Sensors

LET US SOLVE YOUR METERING PROBLEMS

EMT resolve issues with meters and aM&T systems that have been badly fitted and are inappropriate or wrongly installed, systems that have never functioned properly and unsuitable or wrongly configured software.

We have considerable knowledge and can help assess, recommission or replace any aM&T system to render them as useful tools for your utility management needs.

For more information on how we can help, Tel: 01628 664056 Email: enquiries@meteringtech.com www.energymeteringtechnology.com

APRIL 2022 | ENERGY IN BUILDINGS & INDUSTRY | 35

EIBI-MAR20-CMR_Layout 1 26/02/2020 16:29 Page 1

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