Oct 2 Bill Rigos Steinway Solar Thermal

STEINWAY NYC Solar Thermal in Action

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Introductions Bill Rigos – Facilities Manager, Steinway & Sons

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Steinway—Piano Building at a Glance

8 months in 60 seconds

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Piano Building at a Glance (cont)

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Piano Building at a Glance (cont)

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Piano Building at a Glance (cont)

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Steinway—Finished Products

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Part 1 - Project Overview

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Project Background  NYSERDA FlexTech Comprehensive Energy Study  NYSERDA Emerging Technologies Grant – NY Feasibility  ERS Approached Steinway  Site Specific Feasibility  Installation Grant Released  Project Development  Current Installation Status 9

Key Features  Parabolic Tracking Concentrating Collectors  Largest Rooftop System of its Kind  Heat & Cool/Dehumidify  2E Absorption Chiller  “Mature but New”  Industrial Application  Year Round Use  Summer Peak Reduction 10

Project Team Steinway & Sons

GC, Project M anager, owner and operator

ERS, Inc.

Project facilitation Conceptual Design System performance analysis Instrumentation plan System commissioning Grant administration & reporting Mechanical Design & D ocumentation Permitting Control System Design & Integration Structural Design (Installation) Solar 2E absorption system concept design Collector performance modeling Mechanica l Contractor Electrical Contractor

Schuyler Engineering GCF -Inc (controls) Schmi tt Engineering Sustainable Energy Consulting Arista Associated Electric Major Equipment Abengoa IST Broad USA Armstrong

Solar trough supplier 2E absorption chiller supplier, chiller commissioning Steam11 Generator

The Facility – Location Steinway & Sons Manufacturing Facility Astoria, Queens, New York City  40 N latitude  1/3 cloudy, 1/3 partly cloudy, 1/3 clear

20,000 sq. ft. roof  Reinforced Concrete

Progressive Mgt. 12

The Facility (continued)

Action Dept.

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The Facility – Action Dept. Loads Cooling Load  23,000 square feet – Action Department  Top floor of 1960s vintage building  Recent closed loop dust collection project reduced OA by 80% to 1 ACH  No prior AC  70-ton design load estimated Heating Load  Constant 1,200 kBtu/hr process load  Steam heat & humidification in winter 14

The Solar Thermal System

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The Solar Thermal System

Broad 99-ton BZH 30 2E Multi-Energy Chiller 1.59 IPLV COP Steam Generator 900 lb/hr Steam

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38 Abengoa IST PT-1 troughs, 5,700 sf

System Performance (Projected)  340 F hot water to chiller in summer  275 F hot water to generator in winter  Productive starting 9 or 10 am  5%-10% reduction in building solar gain  Annual    

1,400 MMBtu/yr useful solar anticipated 80,000 ton-hr/yr available in summer (1.15 COP) 50,000 ton-hr/yr met with gas firing 870 MMBtu/yr steam generation 17

System Applicability  Suitable for facilities with:  Sustained thermal loads  Sustained cooling loads  Sustained dehumidification loads

 Commercial  Industrial  Variety of latitudes

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Part 2 – The Business Case

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Project Requirements  Action Department  Manufacture wood components  Assemble the piano’s “Action”

 Humidity Control  Component moisture content  Assembly moisture control  Employee Comfort

 Overall Quality

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The Steinway Perspective  Vision for integrating efficiency, leading technologies and continuous improvement in manufacturing  Quality

 Continuous Improvement  Ingenuity  Willingness to explore creative ways of solving problems  Must make business sense 21

The Internal Decision Process  Capital projects are evaluated for:  Productivity enhancement  Quality improvement  Economic payback (ROI, Cash flow – NPV)

 Merit based decision, not PR based  Full justification required for approval at CFO & Executive level

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Economics – vs. RTU Cooling Costs: $1, 200,000 System cost, less ($300,000) NYSERDA cash grant - equipment ($100,000) NYSERDA feasibility study support ( $40,000) NYIRN cash grant ($200,000) 30% federal tax credit* ($200,000) NPV of MACRS+50% bonus 5-yr vs. RTU 20-yr depreciation ($250,000) Avoided RTU cost $110,000 initial incremental cost * 30% is applied to system cost less NYSERDA contribution

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Part 3 – Implementation & Operations

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Design Process  Conceptual Design – feasibility study  ERS  Sustainable Energy Consulting  Steinway

 Detailed Design Process  Steinway – Specific Input & Oversight  Schuyler – Mechanical • Design & Bid Package • Permitting & Expediting

 GCF – Controls  Schmitt Engineering – Structural  ERS – Coordination, Engineering Support

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Bid Process  Multiple Bidders for mechanical installation  Long term relationship with selected mechanical contractor  Lack of familiarity of system (solar, high temp)  Contractors  NYC Department of Buildings

 Cost Escalation & Control

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Installation (continued)

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Installation (continued)

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Installation (continued)

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Installation  Contractor Coordination    

Equipment Vendors Mechanical Electrical Controls

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Installation (continued)

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Installation (continued)

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Installation (continued)

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Installation (continued)  Installation Challenges    

Coordination of key equipment lead times Weather Structural mounting to roof deck Component and controls integration

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Installation (continued)  Operational since Summer of 2010  Commissioning  Monitoring  Reporting

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O & M Considerations  Weather & Seasonal Concerns    

System provides an alarm (local & email) Stow position Hurricane position Winter

 Maintenance    

Array Chiller Steam generator Cooling towers – seasonal use

 Continual Data Acquisition  Weather data, temps, solar insolation, pressures, flow rates 36

Conclusions  Economics work with substantial grants, tax credits & high energy rates  Installation challenges  Heat transfer fluid  Anchoring collectors  Mechanical contractor costs  Coordination  Weather  Chiller less expensive to operate than air-cooled system even without sun  Packaged system could substantially reduce total 37 costs

Control System Display

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Questions?

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Contact • Steinway – Bill Rigos  718-721-2600  [email protected];

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