Services - Digital PRV Control Upgrade

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We would be happy to schedule a walk through to assess your Steam Systems and make recommendations on how to make them more efficient.

Why Switch To Digital Control

PRV stations are the heart of the steam system and should have the capability to be monitored and controlled digitally just like every other major component of building operations.

Provides more precise control

Increases station service life

Decreases valve hunting

Seamless transfer during high and low flow conditions

Increases savings opportunity with more advanced control strategies

 

System Info

Utilize Fisher Controls and Valves

Compatible with most control valves installed (Leslie, Warren, ect) so new valves are usually not needed.

Regulators require upgrade to control valves

 

System is Made up of Three Main Components

  • Main digital Controller
  • Controls all system operations
  • Communicates via ModBus RTU 485 or as a standalone unit
  • Monitors and controls system pressures and individual valve position
  • Easy Touchscreen Control
  • Built in pressure safety control

 

  • Smart valve positioner
  • Mounts to the valve body
  • Measures exact valve position

 

  • Pressure Transmitter
  • Relay exact steam pressures on the station and going out to the steam system

 

Provide Pressure Reducing Valves with built in noise reduction

  • Reduce sound levels up to 12db
  • Helps eliminate system noise issues in tenant spaces

 

Case Study

  • 2.1 M SqFt. Commercial Office Building downtown

  • 4 Pressure reducing stations throughout the building (1 per MER)

  • Utilizes steam for cooling, heating, and hot water generation

  • Large commercial Con Ed steam customer in New York City wanted to lower its operational steam costs.
  • Mosto Technologies recommended retrofitting all 4 of the building’s steam pressure reducing stations with digital control capability.
  • By modulating low end steam pressures based on weather conditions energy savings were generated.
  • Utilized current Leslie control valves
  • Upgraded the controls only
  • System utilizes digital control but valves still operate pneumatically.

Scope of Work

  • Gather valve info and layout of each station
  • Install pressure sensors on the station
  • Install positioners on each pressure reducing valve
  • Install digital Controller to collect data points and control the station
  • Calibrate and commission systems
  • Develop custom control strategies to drive energy savings based on weather conditions and building steam loads
  • Connect each PRV station controller up the building’s BMS system
  • Confirm, track, and develop savings analysis once the system is fully operational

Results / Savings Analysis

Throughout the year, the building’s steam usage was tracked and trended through an online energy monitoring platform developed and supplied by MACH Energy.  Savings were derived by lowering the steam pressures based on outside air temperatures.  During lower load times higher steam pressures are not needed to meet the buildings capacity needs.

  • By lowering steam pressures the buildings was able to reduce its baseline consumption by an average of 500 Lbs per hour.
  • That equals an average of 360 Mlbs per Month
  • 360 Mlbs per Month with an average Con Ed rate of $28 per Mlbs equals $10,000 per month in savings.
  • The project showed a documented payback of 1 year

 

The following chart shows the actual 500 Lbs per hour baseline reduction at the property.

The following chart shows the actual 500 Lbs per hour baseline reduction at the property.  The blue line is the previous baseline, while the orange is the new baseline.  As you can see the baseline was reduced by an average of 500 Lbs per hour.  The steam usage is also much tighter with very little volatility.  This is also a key benefit to the systems digital control capability.

The blue line is the previous baseline, while the orange is the new baseline. As you can see the baseline was reduced by an average of 500 Lbs per hour.

The steam usage is also much tighter with very little volatility.

This is also a key benefit to the systems digital control capability.

Please Call 212.239.1422 or Email to schedule a walk through to discuss the system