Unit 04 Commercial Water Heating-2020training.myescenter.com/commercial_1/Unit_04_Commercial...water (for purposes other than space heating) in tanks and then distributes this heated

© Energy Solutions Center Inc.No portion of this material may be reproduced without the expressed written consent of the Energy Solutions Center Inc.

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Commercial 1 TrackUnit 4 – Commercial Water Heating

1© Copyright Energy Solutions Center Inc. – All Rights Reserved

An overview of Water Heating Technologies

Mr. Eric Burgis, Energy Solutions Center

Track: Commercial Natural Gas I

Unit #4: Commercial Water Heating

© 2020 Energy Solutions Center Inc. – All Rights Reserved


Market Overview

Tank Style Water Heaters

Tankless Water Heaters

Booster Water Heaters

Direct Contact Water Heater

Small Boilers

Heat Pump Water Heaters

Commercial Opportunities

Presentation Outline


Electric57%

Oil2%

District heat0.5%

Propane3%

Natural Gas38%

COMMERCIAL WATER HEATING ENERGY SOURCES

Market Overview Commercial BuildingsWater Heating – Fuel Type Used

EIA, CBECS, Table B13. Selected principal building activity

More than 80% of the 5.5M

Commercial Buildings in the U.S. have some type of water

heating capability.

ConversionOpportunities

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System Use

EIA, CBECS, Table B13. Selected principal building activity

0500100015002000250030003500

CentralizedSystem

DistributedSystems

Combination ofCentralized and

DistributedSystems

Water Heating Equipment (# buildings in 1,000’s)

Centralized Water‐Heating System: A type of water‐heating equipment that heats and stores water (for purposes other than space heating) in tanks and then distributes this heated water throughout the building. A residential‐type tank water heater is an example of a centralized water heater.

Distributed Water‐Heating System: A type of system for heating water (for purposes other than space‐heating) that heats water as needed for immediate use near the location where this water is used. It is often called a “point‐of‐use” water heating system, and is usually located in more than one place within a building. Because water is not heated until it is required, this equipment is more energy efficient.


Natural Gas Consumption for Water Heating by Business Activity

Source: EIA CBECS Table 7

Education13%

Mercantile 14%

Office 7%

Health care 15%

Food service 10%

Lodging 27%

Warehouse and storage

2%

Public assembly 1%

Service 5%

Other 1%

Food sales 1%

Public order and safety

4%


0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021

North America Tankless Water Heater Sales and Forecasted Sales

Electric Tankless Gas Tankless (standard) Gas Condensing Tankless

Tankless Growth Rates

Tankless ShareofWater Heater

Market

2009 7%

2016 9%

2021 12%

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Types of Water Heaters

Tank Style

Tankless


Direct Contact

Boilers

Gas Heat Pump Water Heater

Applications

Commercial Water Heating


Commercial Type SizeMin Thermal Efficiency for equipment manufactured

after Oct 9, 2015 (%)

Electric Storage All NA

Gas‐fired Storage <= 155,000 Btu/hr 80

Gas‐fired Storage > 155,000 BTU/hr 80

Oil‐fired Storage All 80

Gas‐fired Instantaneous All 80

Packaged Boiler ≥300,000 Btu/hr and ≤2,500,000 Btu/hr

80

Packaged Boiler >2,500,000 Btu/hr 82

Title 10 Code of Federal Regulations, Part 431Commercial Water Heater Efficiency

Units <= 199,000 BTU/Hr are typically use Energy Factor or UEF, while larger inputs use Thermal Efficiency.


Current Residential Water Heater Efficiency

2015 Standards (Residential): GAS – Common Sizes

2015 DOE (Department of Energy) Final Rule Effective April 16th, 2015

Applies to residential water heaters, but these are used in small commercial applications as well.

<= 55 Gallons > 55 Gallons

Calculation EF = 0.675 – (0.0015 x V) DF = 0.8012 – (0.00078 x V)

Rated Storage Volume

Tankless 30 40 50 60 65 75

Older Standard

.62 .61 .59 .58 .56 .55 .53

2015 Standard

.82 .63 .62 .60 .75 .75 .74

Non‐Condensing

Condensing

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Commercial Water heater Shipments (U.S.)

‐

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

2015 2016 2017 2018 2019

Commercial Storage Water Heater Shipments

Commecial Gas Commercial Electric

http://www.ahrinet.org/statistics

The increase in commercial electric water heaters is likely from the residential market where these are being installed instead of electric heat pump water heaters for anything >= 55 gallons since 4/16/15


WaterHeating

Technologies

© Copyright Energy Solutions Center Inc. – All Rights Reserved

Tank Water Heater



Direct Contact Water Heaters

Boilers

Heat Pump Water Heater

Commercial Water Heaters

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Most common

Least expensive

Flexible

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Tank Style Water Heater

Hot water outlet

Cold water inlet

Pressure /temperaturerelief valve

Vent pipe

Flue tube /heat exchanger

Flue baffle

Anode rod

Insulation

Gas burner

Combustion airopenings

Thermostatand gas valve


Tank Water Heater Offerings

Atmospheric Direct Vent Power Vent

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Sizing Commercial – 35 gallons up to 300 gallons (132‐1,135 liters)

Efficiency DOE minimum standard: 67% residential, 80% commercial (apply derate of residential efficiency based on storage volume) Best available technology: 98% residential , 99% commercial

Considerations Standby loss & Recovery Rate First hour rating

Tank Style Water Heater


399,000 – 2,000,000 BTU Input125, 250, and 300 (473, 946, and 1,135 liters) Gallon TanksUp To 99% Efficiency (low fire)Full Modulation with 10:1 TurndownProgrammable Electronic Control with Digital Temperature ControlCategory IV Venting with CPVC Vent Material10 Year Tank Warranty3 Year Scale Warranty

High Efficiency Storage Water Heater


Microprocessor controls Tank maintain consistent temperatures Integrated mixing devices Allows for storage of hotter water – increasing amount of usable hot water available

Set back controllers Similar to programmable thermostat Leak detection devices Shuts off water if tank leak is detected Atmospheric flue dampers Reduces standby losses

Intelligence for Tank Water Heaters

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Advanced Temperature ControlsMicroprocessor constantly monitors and controls burner operation to maintain consistent and accurate water temperature levels

Intelligent Diagnostics Provides diagnostic codes to assist in troubleshooting

Microprocessor Controls

CONTINUED


Self powered Thermopile converts heat energy from the pilot flame into electrical energy to operate the gas valve and electronics

Retrofit replacement Service kits are available for direct replacement on certain units

Microprocessor Controls


Allows water in the tank to be stored at higher temperatures

Increases usable hot water by as much as 50%, while controlling the hot outlet at a lower temperature

Integrated Mixing Device

CONTINUED

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Mixed Hot Water Outlet

½” NPT Un‐Mixed Hot

Water Outlet

½” NPT Recirculation Inlet

¼” NPT Cold Water Outlet

Cold Water Inlet

*ASSE and UPC (IAPMO) Certified

Stainless SteelFlexible Connector

Push to TurnHand Wheel

Integrated Mixing Device


Similar user interface as heating/air conditioning thermostats

7 day/4 period programmable display

Battery backup in case of power failure

Can be remotely wired

Hot water capacity indicator; provides an estimate of available hot water in the tank

Energy savings of between 7% to 36%

Set Back Controller


Set Back Controller

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Electronic sensor designed to detect leaks Triggers an alarm to alert business when a water heater leak is detected Installs in water heater drain pan Components are re‐usable – can be removed and installed on a new water heater

Leak Detection

CONTINUED


Mounts on water heater inlet Shuts off the inlet water after a leak is detected and confirmed Requires electrical power to actuate valve Easily installed with provided bushings

Leak Detection Inlet Shut Off Valve


Reduces stand‐by loss resulting in less gas consumption and higher EF Ratings

Damper blade opens and closes automatically during operation and stand‐by mode

Requires power to control damper

Atmospheric Flue Damper

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Commercial Fire Tube Condensing

CombustionChamber

Removable dual heat exchangers

Four passes of combustion gases through the water

PVC venting

Low NOx burners available



Standard Models Condensing Models

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(Internal View) Temperature is set via the controller

Water tap opens & water begins to flow

Turbine spins & sends signal to PC Board

PCB determines water flow, firing rate & temperature

Combustion fan motor starts

Burner is ignited by direct electronic ignition and unit fires then modulates to match input with hot water flow

When hot water tap is turned off – The unit returns to standby mode

How it Works

Filter

GASWATERINLET

HOT WATEROUTLET

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The difference of the incoming ground water and the tankless water heater’s set point temperature is known as Delta T (∆T) Delta T determines the flow rate of the tankless water heater

What is a Delta T (∆T)?

EXAMPLE:The Tankless temperature is set at = 120°Subtract the incoming temperature from the water heater’s set temperature for ∆T:120° ‐ 57° = 63° ∆T


Understanding Flow Rate

EXAMPLE (from previous page)

Subtract the incoming ground water temperature from the water heater’s set temp. for ∆T 120° ‐ 57° = 63 °

The maximum GPM flow rate for any given ∆T can be found at the intersecting points along each model’s specific flow curve

The tankless water heater’s first priority is to provide the set point temperature to the user. Based on the ∆T, the tankless product may regulate flow to ensure it can provide the selected temperature.

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If incoming water is 57° and requested temperature is 120°, ∆T is 63° and gpm flow rate is 5.1 gpm

Colder Inlet Water


Sizing Up to 380,000 Btu/hr

Efficiency DOE minimum standard: ~82% Best available technology: 98%

Benefits Higher flow rates than electric Compact size Long‐life – 20 years or more Easy to service and repair

Gas Piping Requirements – ¾” gas line 5.0 inches wc minimum (12.7 centemeters)


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Typical Manifold Installation Options

140140

Expansion TankCold WaterSupply

Gas SupplyTo Hot Water Supply

Remote Control


Recirculation Pumps

140

ExpansionTank

Cold WaterSupply

LOADS

Hot Water Supply

RECIRCULATION LOOPPump

Check Valve(Required)

Controlled by an Aquastat, Timer and/or both

Sized to maintain circulation loop temperature

Sized to overcome pressure loss through water heater supply and return plumbing


Typical Commercial Manifold with Direct Recirculation

140140

ExpansionTank

Cold WaterSupply

Gas Supply

To HotWaterSupply

RemoteControl

140

ManifoldController

Heavy Duty Heaters

Pump

ReturnCirculation Line

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Tankless models fit in a variety of commercial applications such as: Restaurants Hotels Multi‐family housing

Government buildings such as schools

Car washes Coin laundries Gyms

Others

Good applications for Tankless Water Heaters in the Commercial Market



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Designed to heat rinse water for better cleaning with fewer spots – especially on glassware

Heats hot water from 120°‐140°F (48.8‐60°C) up to 180°F (82.2°C) water

Improves cleaning and sanitizing of dishes

Shortens drying time

Less wear & tear on dishwashing equipment and dishware

Eliminates need for chemical rinse aids

Environmentally friendly


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Does not effectively remove food and soil, resulting in a dish that is not visibly clean and may need re‐washing 140°F (60°C) water temperature does not melt fats or proteins such as lipstick If water hardness is over 6‐7 grains, spotting of dishware occurs Chemical effect on metals & etching of glasses and china Longer drying times due to low rinse temperatures

Low Temp Dishwashing


High temperature cleans better, especially on lipstick and grease residues. Dishes flash dry with high temperature giving you quicker turnaround and less water on the floor. High temperature units reduce chemical, water and sewer usage. Labor reduction & increased production (Reduce re‐washing dishes) Safety in the workplace (Less water on floor means less slip and fall injuries)

Other Booster Water Heater Advantages



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Stainless steel rings promote 99% efficient heat

transfer

Cold water inlet

Hot water outlet

City water pressure through an engineered nozzle creates a specific spray pattern

Market Opportunities

Laundries Foodservice

Facilities

Not intended for installations where water is re‐circulated


City water pressure feeds cold water into a vertical tower The cold water falls by gravity through an area filled with stainless steel packing rings The burner provides hot combustion gases to the vertical tower of the heater – where the hot gases come into direct contact with the falling water Rings increase the available surface area inside the tower to transfer heat and also keeps the water broken into smaller droplets


CONTINUED


Droplets have a smaller diameter, enabling them to take on heat with nearly 100% efficient heat transfer

As the combustion gases rise through the unit they transfer heat to the water falling in the opposite direction and are cooled until they exit through the stack

Exhaust gases are close to the same temperature as the temperature of the water spraying through the top nozzle and are at near 100% relative humidity


CONTINUED

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The heated water falls down into the reservoir or storage area at the bottom

A distribution pump, will deliver the hot water, on demand or continuously at the needed discharge pressure and desired temperature



Direct‐Contact Heater ‐ Thermal Efficiency100

90

80

70

60

50

4060 70 80 90 100 110 120 130 140 150 160 170 180

Exhaust Gas Exit Temperature

Therm

al Efficiency

Typically, direct contact water heaters have an exhaust temperature about 10‐20°F (‐12 to ‐6.6 °C)

above the incoming water temperature

Quikwater presentation, June 2011

15.5 21.1 26.6 32.2 37.7 43.3 48.8 54.4 60.0 65.5 71.1 76.6 82.2 Deg. CDeg. F


Large Commercial Use Savings Example

$236,503$265,051

$303,683

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

Direct Contact Direct Steam Indirect Steam

Annual Gas Costs For Water Heating SystemsBased on 60 to 140 F; 250,000 gallons/day use

Quikwater presentation, June 2011

Annual Gas Costs for Water Heating SystemBased on 60 to 140°F (60°C); 250,000 Gallons (946,352 Liters) / Day Use

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Boilers for Larger Hot Water Needs

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Contains multiple cast sections

Unit sizing up to 150 hp New Condensing Boilers available Efficiencies approaching 97%

Sectional Boilers


The furnace/burner section is a single large‐diameter tube with many small diameter tubes connected to it

The small‐diameter tubes are arranged above the burner section to provide a larger heating surface area to heat the water

Burner and tubes are contained entirely within an outer boiler shell that contains the water being heated

Sizes ranges from 100 to 1200 horsepower

Small Fire Tube Boilers

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Water circulates inside tubes heated externally by the burner

Fuel is burned inside the furnace, creating hot gas which passes over the water tubes, heating the water in the tubes

Typically larger than Fire Tube boilers

Small Water Tube Boilers


Water passes through boiler tubes while combustion gases remain on the shell side passing over the boiler tube surfaces

Unlike conventional water tube boilers, the tubes are fitted with fins that increase the area available to transfer heat to the water

Finned Tube Boilers


Ultra‐High Efficiency Condensing Technology –up to 98% Thermal Efficient (95%+ AFUE)

Stainless Steel Heat Exchanger

Ultra Low NOx emissions ‐ SCAQMD approved

Designed for low maintenance and easy serviceability

Fully adjustable outdoor reset technology with the sensors available

Domestic Hot Water has Priority over hot water used to provide space heat

Condensing Wall Mounted Boiler

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Commercial Heat Pump Water Heater

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Heat is extracted from the environment

A Natural Gas engine replaces the electric motor to drive the system compressor

The Engine also produces waste heat that is recovered to supplement the heat supplied by the heat pump

The Engine drives a small electrical generator to provide electricity for fan motors, pump and controls

Efficiencies up to twice that of a gas‐fired boilers

Natural Gas Engine‐Driven Heat Pump Water Heater


Commercial Heat Pump Water HeaterAmbient Outdoor Temperature: 75°F (23.8°C)Hot Water Delivery Temperature: 120°F (48.8°C)COP = 586,000 / 292,000 = 2.0

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400,000‐600,000 BTU/Hour (4‐6 Therms) Ford 2.3 L 4 Cylinder Engine (<50 bhp) Ultra Low Emissions Small 5 kW generator for parasitic load Next‐generation control system – Internet‐Based Touch‐screen display Advanced communications (CAN) Efficient, low‐pressure, HFC‐134a refrigerant Open‐drive reciprocating compressor Custom evaporator coil design Compact brazed plate condenser

Gas Heat Pump Water Heater Specifications


Electric Heat Pump Water Heater

Hot water outlet

Cold water inlet

Pressure /temperaturerelief valve

ResistanceElements

Anode rod

Insulation

Drain

Upper Thermostat

Lower Thermostat

FanCompressor

Evaporator

Condenser

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Requires installation in locations that remain in the 40°–90°F (4.4°–32.2°C) range year‐round

Install them in a space with excess heat such as a furnace room

Generally cost 2X that of a Gas tank water heater ($1660 versus $850 for gas unit installed)

Only save about $30/Year over a gas tank unit, or about 50% over electric tank unit

Electric Heat PumpWater Heating Systems

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Gas Heat Pump Water Heater

1.6 Average Cycle COP

EF: 1.3 First Hour: 60 – 80 gallons Heating Output: 10,000 ± Btu/hr (3 kW) Emissions: SCAQMD Compliant

GHPWH

Simple

Savings Consumer Installation Installed Payback Market

Capacity EF $/yr $/yr Cost Cost Cost [yrs] Size

Electric Heat Pump 50 gal 2.00 $271 $129 $1,100 $600 $1,700 6.2

Electric Resistance 50 gal 0.95 $570 $428 $375 $400 $775 4.0

Gas Heat Pump 65 gal 1.30 $142 $1,800 $700 $2,500 Base Case

Condensing Gas Storage 50 gal 0.82 $225 $83 $1,600 $800 $2,400 1.2

700,000Condensing Gas Tankless 199 kbth 0.90 $205 $63 $1,200 $1,000 $2,200 4.76

Non‐Condensing Tankless 199 kbth 0.82 $225 $83 $900 $1,200 $2,100 4.8

Power Vent Gas Storage 50 gal 0.67 $276 $134 $1,000 $600 $1,600 6.7

Standard Gas Storage 50 gal 0.62 $298 $156 $550 $500 $1,050 9.3 4+ million

* Data from June 2015 TMAF presentation

Opportunity


Gas vs Electric Water Heater Comparisons


First Hour Rating

Recovery rate

Water Heater Cost Comparisons

Energy

Installed Costs

Life Cycle Costs

Emissions62


Gas vs. Electric Tank Water Heater

GPH Recovery at 90 Deg F = 20.7GPH Recovery at 90 Deg F = 40.5

Source: Lowes.com

Whirlpool 40 Gallon Gas, .67 EF Whirlpool 40 Gallon Electric, .92 EF

First Hour RatingGas 67 gallons

Electric 50 gallons

Gas unit provides 34% more hot water in the first hour.

Gas unit recovers twice as fast as the electric unit once cold.

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Canadian EnerGuide Labeling System

Canadian EnerGuide System

Gas Label Electric Label


Life Cycle Cost Analysis

Years

New System Water Heating System

installed year 1Annual Costs include: Capital Cost Energy Cost Tank replacement in year 12 for all tank models Assume 24 year Life for tankless model

1 23

4

5

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11121314

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2324

Tank Replacement


Life Cycle Costs

Electric TankWater Heater

GasWater Heater (Power Vent)

Standard Gas Tankless

Water Heater

Condensing Gas Tankless Water Heater

Installed Cost Yr 1 $750 $1,200 $1,800 $2,500

Tank Replacement Yr 12 $750 $1,200 $0 $0

Year 1 Operating Costs $574 $238 $195 $166

12 Year Life Cycle Cost $8,030 $4,056 $4,140 $4,492

24 Year Life Cycle Cost $16,983 $8,112 $6,480 $6,484 * Assumes that electric pricing increases 1% a year, and that gas prices will hold stable for the foreseeable future.

The payback on the initial tankless investment alone does not do justice for this technology. Simple paybacks do not account for the longer lifespan of the tankless water heater or the comparison to larger gas tank models for larger usage

Life Cycle Costing

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Uses less energy – costing about ½ as much to operate versus electric

Rapid recovery – 3 times faster than electric tank units

Style and sizes to fit most installations

Tank style

Tankless – Never run out of hot water

Long life – 20 years or more with tankless

Benefits of Natural Gas Water Heating


Commercial Opportunities –Water Heater Applications


15 GPM (56.7 LPM) at 165°F (73.8°C) to fill Zamboni storage tank at ½‐1 hour intervals

Prior system was gas fired tanks lasting 1.5‐2 years

Monthly fuel savings realized by tankless is $3,000

Ice Rink – Zamboni Filler

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70© Copyright Energy Solutions Center Inc. – All Rights Reserved 70

Eat‐In Restaurant Application

New Installation

Multi‐temp system meeting all kitchen & public washroom requirements


Hotel Tankless Application

Hotel tankless system Providing over 100 GPM (378.5 LPM) / 4,400 GPH (16,655.8 LPH) Retrofitted to old boiler room location


Residential – Condo Application

33 Story ‐ 387 Unit Condominium 3 condensing boilers for domestic hot water and base load heating 3 Boilers for retail hot water 3 condensing boilers for domestic hot water in recreation facility

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Elementary School – LEED Building

LEED building 75,000 ft2 (6,967.7 m2) facility Two A.O. Smith Cyclone XHE® gas water heaters rated at 94% thermal efficiency


Fitness Center Conversion

10 tankless water heaters replaced (2) 2,000,000 BTU boilers and 1,800 gallons (6,813.7 liters) of storage This system runs 42 showers and 10 lavatories


Drive‐In Restaurant

Installing tankless water heaters in all new construction restaurants

Restaurant

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Thank you …

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Documents

Unit 04 Commercial Water Heating-2020training.myescenter.com/commercial_1/Unit_04_Commercial...water (for purposes other than space heating) in tanks and then distributes this heated