Minnesota campus saves with heating retrofit during record lows

MAGNA3 pumps run at 25% less head of old units PHOTO: Dave Schlumpberger, HVAC Service Technician at St. John’s University, says the new Grundfos MAGNA3 pumps run the system at the original designed flow rate using less power, less energy and at less cost.
MAGNA3 Case Story

Minnesotans have a well-earned reputation for toughing out the snow and cold each winter, but even this US state was tested over the harsh 2013-2014 edition. Record lows put heating systems across Minnesota to the test. While many commercial buildings required more energy to keep tenants comfortable with below-freezing temperatures, one private school actually saved money.

Saint John’s University, an all-male, Benedictine school in the town of Collegeville, undertook a heating system retrofit just in time. Campus HVAC Service Technician David Schlumpberger oversaw the project:

“We were approached by our local wholesaler, Ferguson Enterprises, with the suggestion that we consider replacing the pumps in the Peter Engel Science Center with Grundfos MAGNA3 smart circulator pumps,” he says. “I wasn’t aware of them before, but the existing pumps were nearing the end of their lives, so we decided, ‘Why don’t we do something more efficient?’”

Energy efficiency is important on every campus, but environmental stewardship is a core Benedictine tradition at St. John’s, which boasts an Office of Sustainability and sits on 2,700 acres that range from wetlands to lakes and prairies to forests. “The MAGNA3 smart technology is a really good fit for a school that teaches students a respect for the land,” Schlumpberger explains.

Schlumpberger and his team opted for the MAGNA3 circulators due in large part to the products’ sophisticated electronic technology and demonstrated energy efficiency. Although the MAGNA3 has a higher initial cost than most conventional circulators, its powerful performance produced fast payback on that investment at St. John’s.

A Logical Solution
The MAGNA3 is an energy‐optimized, variable-speed, wet rotor circulator that features a permanent magnet motor design that cuts power consumption up to 85 percent — the highest energy efficiency rating as compared with other circulators in its class.

“These pumps adapt to existing situations and can be adjusted accordingly,” says Brian Soderholm, a Grundfos sales representative in Ramsey, Minnesota, who worked on the St. John’s project.

PHOTO: The new MAGNA3 pumps brought energy savings of between 58-84% in the St. John University building’s four wings.

“Grundfos is the only manufacturer that offers a pump that has an integrated logic algorithm to ‘learn’ the varying energy-usage patterns of any application. This was a huge improvement over the Science Center’s antiquated pumps,” Soderholm adds.

Replacing the four older pumps with the MAGNA3’s increased efficiency and improved building comfort. The pump’s signature feature is the AUTOADAPT function, which continuously fine‐tunes power consumption, discharge head and flow rates to meet the dynamic needs of the system.

MAGNA3 installation
With its four building wings, the Peter Engel Science Center runs heat from fall through spring. It was built in the 1960s of concrete, typical of that era and of the construction style found throughout the rural campus.

“We had a feeling the old pumps were oversized, but there was no way to tell — until we did the replacement,” Schlumpberger says.

The building contains two primary circulators, pumping hot water supplied by a steam-to-hot-water convertor. The steam comes from a central plant. There are four pumps on the secondary loops – each serving a different wing – feeding baseboard heating that uses pneumatic, three-way mixing valves to help regulate the temperatures.

Initially, Schlumpberger and his team thought the outdated pumps were on a variable flow system. “But after the pumps were installed and we started it up, we realized that the system was not variable. It was a fixed flow,” he says.

Since the building was not zoned and no variable frequency drives were installed, the entire system was operating at full power throughout the heating season. The team performed an audit of the existing pumps and found that the older system was oversized.

“Oversizing wastes energy and is hard on the pipes,” says Soderholm. “In fact, we saw evidence of that in some copper piping that Dave’s staff removed. The insides of the piping were lined with ridges, indicating damage from excess velocity.” (See photo)

PHOTO: Insides of copper piping at St. John’s were lined with ridges, indicating the damage caused by the older, oversized pumps.

The intelligent technology of the four new MAGNA3 minimises energy costs. The pump has a built-in energy meter and a flow-limiting function. Even at reduced loads, these circulators save energy compared with conventional circulators. They are also an all-in-one option for building owners, eliminating the need for costly installation of a companion flow meter, pressure and temperature gauges, throttling valve, constant-speed pump or BTU meter.

With this circulator, Grundfos makes it easier to right-size the duty point, Soderholm says.

“With the MAGNA3s, we were able to get the necessary flow rates at much fewer feet of head [at lower pressure],” Soderholm says. “Over time, I think they’ll be able to slash their energy use even further. Even though this was not a system with variable-flow characteristics, the payback numbers are still really impressive.”

Encouraging payback results
When looking at the premium of going with the four MAGNA3 units versus another brand in its class, the payback for the Science Center will be under three years for three of the new circulators and just slightly longer for the fourth. “We sized the pumps to match the old pumps, not knowing what their true system requirements were,” Soderholm says, explaining they had only the rating plates to go by, since their analysis was conducted during summer.

“Even though the Grundfos pumps are larger than necessary for this building,” he continues, “it’s not wasteful, because we were able to dial them down with impressive results.” (See table.)

That translates into an estimated yearly savings of $693.  

TABLE: The new MAGNA3 circulator pumps brought up to 84% savings and a three-year payback time at Saint John’s University. Meanwhile, they helped improved the indoor comfort, according to HVAC Service Technician David Schlumpberger. (Note: 1 US gal = 3.8 l, and 1 ft = 0.3 m)

“The bottom line is that the MAGNA3 is sophisticated and capable of doing everything the old pumps did, only better because it’s smart,” says Schlumpberger. “It can tell itself to slow down or speed up, based on current demand. Another benefit is that now we can get data off the pumps’ readout and learn more about the building’s needs.”

Schlumpberger adds: “We just had the coldest winter in 30 years and we were running pumps at 25% of the head that the old pumps had, while keeping the building warm. In other words, we’re actually able to run the system at the original designed flow rate, using less power, less energy and at less cost.”

Story by Julie Reynolds
Photos by Craig Lassig

"We are able to run the system at the original designed flow rate, using less power, less energy and at less cost."

St. John’s University HVAC Service Technician David Schlumpberger

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