Hans-Georg Baunach

Hans-Georg Baunach

Management

1 Nov 2017

Well thought-out planning for low operating costs

Small investments open up huge savings potential in the Lebenshilfe residential facilities in Altdorf

When the focus of property planning is not only on low construction costs but also on low operating costs, architects and planners must demonstrate their expertise. This was the objective for the “Inclusive Living Environments” project by Lebenshilfe im Nürnberger Land.

With tailor-made planning and off-the-shelf technology, it was possible to optimise heat supply and electricity generation – the core components, a combined heat and power plant and heat storage system work together perfectly for this purpose.

Fig. 1: Some areas, such as the interior communal areas (picture), the foyer, the corridors and the meeting rooms of the inclusive living environments, are supplied by decentralised ventilation systems.

Lebenshilfe im Nürnberger Land e. V. operates over 20 properties where people with developmental delays or disabilities can find a home and receive care. The residents are usually assisted by permanent employees of Lebenshilfe. However, a new approach is being pursued in the young “inclusive living environments” in Altdorf. The property, which was first occupied in spring 2016, offers living space for people with disabilities and for people without disabilities. The latter can get involved in providing care, for example by cooking or organising leisure activities for the working people with disabilities, and receive a flat-rate volunteer allowance for this, which in turn reduces their rental costs. For the inclusive living concept, Lebenshilfe built built a building with 26 apartments for people with disabilities and five additional apartments for tenants without disabilities. The building has three floors, each with a gross area of approximately 2,500 m².

The ground floor includes a lounge and conference room, a café with its own large kitchen, and various utility and technical rooms. The first and second floors house the residents’ apartments – each with its own bathroom and anteroom – as well as two communal kitchens and large communal areas per floor. In addition, there is a care bathroom and utility rooms in the central area.

”Reason prevailed in planning and construction”

Fig. 2: An exergy-optimised cascade of fresh water stations helps to maximise the temperature spread – and thus the thermal efficiency – of the entire system.

Around £5.5 million was invested in the construction of the “Inclusive Living Worlds”. Two-thirds of this was financed by subsidies, with the rest contributed by Lebenshilfe. Since the Altdorf residential complexes were financed from public and private funds and the rents were to be affordable for the residents, the property was designed by Prof. Dipl.-Ing. Hans Peter Haid (managing director of Haid+Partner GmbH Architekten+Ingenieure, Nuremberg) with the aim of achieving “high efficiency”. The architect, who specialises in healthcare and social buildings, spoke to prospective residents before the designs were drawn up and incorporated their wishes and ideas into the concept. The result is a building with a “green” roof and a “green” basement. The architect, who specialises in healthcare and social buildings, spoke to prospective residents before drawing up the designs and incorporated their wishes and ideas into the concept. The result is a building with a highly insulated outer shell and a good layout, which does without large glass fronts, thus ensuring low heating costs. The focus of the planning for the technical building equipment was on the tasks and residents of the facility. “In addition, well thought-out and easy-to-use equipment makes life easier for the residents,” explains specialist planner Roland Müller. The planning for the technical building equipment focused on the tasks and the residents of the facility. “Well-designed and easy-to-use equipment makes life easier for the residents,” explains specialist planner Roland Goetz from Altdorf, describing one of the project requirements.

Fig. 3: Specialist planner Roland Goetz in front of the multi-way distributors. They make the return flow of a high-temperature heating circuit usable for the flow of a low-temperature circuit. This maximises the temperature spread and thus the thermal efficiency.

For example, the barrier-free bathrooms can be equipped with additional grab rails and all washbasins in the building are wheelchair accessible. Even features that are not immediately visible, such as the anti-scald mixers installed throughout, reveal that no corners were cut, but rather that safety and durability were the primary considerations when making investments.

Classic heating and ventilation in the apartments

Conventional radiators with thermostatic valves installed under the windows are used to heat the flats. In the bathrooms of the flats, stale or humid air is extracted. The resulting suction effect ensures a constant supply of outside air through outside air vents located behind the radiators under the windows. In addition, all windows can be opened if necessary.

Only the communal areas and rooms are ventilated entirely by machine. Ventilation units with heat recovery (via plate heat exchangers) are installed in kitchen wall cabinets or wall cupboards for this purpose. The units supply the respective ventilation zones via short ducts, minimising pressure losses. Low fan speeds and careful carpentry ensure that the ventilation technology is unobtrusive, both visually and acoustically.

CHP covers basic heating requirements

In addition to the concealed, decentralised ventilation units, specialist planner Goetz also designed the entire technical infrastructure. For heat generation, he chose a natural gas-powered small CHP (combined heat and power) unit from Viessmann with an electrical output of 6 kW and a thermal output of 15 kW. This is supplemented by an 80 kW peak load condensing boiler. Both transfer the heat to a buffer storage tank from varmeco with a capacity of approximately 3 m³ of water. “The storage tank supplies all of the building’s heat consumers,” explains Goetz. “The CHP unit is large enough to cover more than half of the total heat demand, thus meeting the requirements of the Renewable Energy Heat Act. On the other hand, its output is small enough to run in base load mode – i.e. long running times with few starts and stops, which is made possible by the use of the storage tank,” says Goetz.

The CHP plant is temperature-controlled. If the sensor at the top of the storage tank reports a temperature below 65 °C, the CHP plant’s control system switches on the engine. The temperature of the water in the lower part of the storage tank, which is pumped to the CHP plant for heating, is irrelevant for its operation: A speed-controlled feed pump ensures that the CHP plant always operates at a constant speed. If the water is cool, the pump reduces the flow rate to such an extent that the CHP plant always operates at a constant speed. A speed-controlled charging pump ensures that the CHP plant always operates at a constant rate. If the water is cool, the pump reduces the delivery rate to such an extent that the dwell time is sufficient to heat the water to more than 80 °C. “This is the only way to implement condensing operation that maximises the output of the CHP unit. It should be noted that not all CHP units are suitable for utilising the exhaust gas heat with condensing technology,” adds the planner, “but the installed system allows the exhaust gas to be cooled significantly and is also the perfect size for this property.” With up to 75 kW, most of the heat output is available for the radiators in the external rooms. Another heating circuit serves the heating requirements of the nursing bathrooms in the central areas of the floors with a maximum output of 3.5 kW at a flow/return temperature of 70/50 °C. Up to 13.4 kW at 40/25 °C is available for the heat exchangers in the ventilation systems. The industrial laundry dryer can draw a further 10 kW: the Up to 13.4 kW at 40/25 °C is available for the heat exchangers of the ventilation systems. The industrial tumble dryer can draw a further 10 kW: even the industrial washing machine usually manages without electrical heating energy, as the building services provide up to 16 l/min of rainwater at a temperature of 60 °C. Only drinking water is used for the final rinsing of the laundry. For higher washing temperatures (boiling laundry), the electric heating of the washing machine brings the water to 80 °C. Only for the final rinsing of the laundry is hot drinking water used. For higher washing temperatures (boil wash), the electric heating of the washing machine quickly brings the water up to temperature with 18 kW.

Three-chamber distributor for optimum temperature distribution

“In order to achieve the greatest possible temperature spread in the heat exchanger, we use a three-chamber distributor.

explains Goetz.

“With these systems, it is possible to utilise the high return temperature of a circuit of, for example, 50 °C for the flow of a low-temperature system of, for example, 40 °C – in this project, the ventilation systems,” he says. “In total, this hydraulic optimisation leads to lower return temperatures at the storage tank and thus increases the overall efficiency of the system.”

he says.

“Overall, this hydraulic optimisation leads to lower return temperatures at the storage tank, thereby increasing the overall efficiency of the system.”

Fig. 4: The industrial washing machine (front) and the tumble dryer. Both operate using heat from the CHP unit; only during the boil wash programme does the washing machine provide additional heating via electricity.

The hot water supply is also designed for minimum return temperatures. The hot water is provided by varmeco water flow heaters, known as fresh water heaters. This means that hot water throughout the house is only heated on demand using the flow principle.

“This minimises the risk of Legionella bacteria growth and thus ensures maximum hygiene,”

emphasises Goetz. It is an exergy-optimised two-stage cascade that delivers up to 5 m³/h of water at a maximum temperature of 75 °C in the flow.

The cascade also draws its thermal energy from the varmeco storage tank, with heat being supplied as required by means of a speed-controlled pump.

Low return temperature for hot water preparation

In the exergy-optimised circuit, the heating tasks are separated:

“The two-stage cascade contains a fresh water heater for drinking water heating only and a second one that covers peak demand and tempers the circulation water.”

Fig. 5: The back of the washing machine protrudes into the neighbouring room. Here, the clean laundry is taken out of the washing machine and put into the dryer.

Separate piping results in a low return temperature in this system; in this case, the water ideally flows back to the storage tank at 35 °C. Due to the weather-independent heat loads in the building, such as the frequently running washing machine and tumble dryer, the CHP unit is well utilised throughout the year. It runs for around 6,500 hours per year. In summer, when only hot water is needed for showering, washing and rinsing, or heat for the laundry room, it runs for around eight hours. It runs for around 6,500 hours per year. In summer, when only hot water is needed for showering, washing and rinsing, or heat for the laundry room, it runs for around eight hours per day.

“Thanks to the generous volume of the heat storage tank and the wide temperature spread, the CHP unit operates efficiently and with low cycling,” reports the planner. Around 200 starts per year minimise wear and tear.

Central heat control with remote access

Fig. 6: Barrier-free bathrooms are a standard feature of all apartments in the “Inclusive Living Worlds” in Altdorf.

Heat management is handled by the central varmeco “VarCon 380 Pro” control system, which allows the operating data to be parameterised and displayed on the device or – via a secure, password-protected internet connection. For example, the control system requests boiler operation when the output of the CHP unit is not sufficient to cover the heat demand. The CHP unit is therefore always used with priority. The control system also manages the heating circuits and hot water preparation, including all pumps. Since the pump drives are speed-controllable, they allow for demand-oriented and energy-saving operation.

As the pump drives are speed-controllable, they allow for demand-oriented and energy-saving operation.

Fig. 7: The varmeco control system allows heat sources to be prioritised. This gives the CHP unit priority over the condensing boiler and runs for around 6000 hours per year.

CHP covers half of the electricity demand

Fig. 9: A Viessmann CHP unit (front) and a 3 m³ varmeco heat storage tank (rear left) supply the “Inclusive Living Worlds” with heat. The system is supplemented by an 80 kW peak load condensing boiler.

The harmonious interaction between heat supply and electricity production in the small CHP plant is due in no small part to its precisely tailored size. The summer base load and the heating demand in

the transitional seasons can be covered by the CHP unit alone; the condensing boiler is only required on relatively cold days.

“The simultaneous electricity generation, which accounts for around 30% of the CHP unit’s total output, is ideal for providing electrical energy for cooking, refrigerators and freezers, ventilation systems or the additional heating for the washing machine. As a result, only one tenth of the CHP electricity has to be fed into the grid and 90% is consumed immediately in the house. This in turn covers about half of the total electricity demand,”

Goetz concludes.

In view of the low remuneration for CHP electricity compared to the price of electricity, the simultaneity of generation and consumption of electrical energy means additional savings. This is possible not least thanks to the fact that heat supply and consumption are decoupled by the 3 m³ storage tank.

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