High Performance Buildings 2006 AABC Commissioning Group (ACG) April 6, 2006

Retro-Commissioning for Energy Efficiency

Making buildings work. Better.

Tom Poeling, P.E., CEM, LEED AP E M C Engineers, Inc.

Agenda Retro-Commissioning for Energy Efficiency

What is Retro-Commissioning? Define Benefits of RCx Define RCx Process Discuss RCx Findings
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What is Retro-Cx (R-Cx)

Systematic process for improving the current condition and operation of an existing building. Typically addresses:
HVAC, Controls Lighting Controls Envelope

Evaluates the condition of buildings systems and optimizes the operation, performance, and maintenance in accordance with the Owner's current operational needs, including reducing energy consumption. Typically performed on a building which was never commissioned.
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Why R-Cx Anything?

Poor initial design, equipment selection Space complaints temperature, IAQ, etc. Multiple renovations Room changes from original intent Modifications to system components Changes to controls sequences, set points Building is not operating efficiently against benchmarks THINK ABOUT IT AS A BUILDING TUNE-UP!!
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Beyond Quick-fix
Retro-commissioning (Retro-Cx) goes beyond quick fix Determine root causes of problems Optimize building systems Control sequences that are optimized for efficient and effective operation Often reduces or eliminates need for capital improvements
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Retro-Commissioning Benefits
Corrections are typically low cost measures to implement Savings are realized in energy cost, O&M costs, avoided capitaltypically 5% to 20% in energy costs alone Paybacks typically 6 mo to 2 years 50% to 200% ROI Allows for training O&M staff to sustain ongoing building performance improvement
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Retro-Cx Addresses Energy Savings Demand Savings (less opportunity than electrical consumption savings) Natural Gas Savings Operational Issues (IAQ, comfort problems, broken systems, etc.) Deferred Maintenance Issues

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Where does Our Energy Go?

Transportation 27% in 1997 and 2004 Industrial 38% in 1997, 33% in 2004 Buildings 36% in 1997, 40% in 2004 In Buildings - Approximately half in Residential and half in Commercial Electrical Capacity 70% to Buildings
*Source: Energy Information Agency

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Retro-Commissioning Process

Retro-Commissioning Phases
Planning Phase
Assess BAS capabilities, potential opportunities, and Investigation approach.

Operating Phase
Report operating improvements made and train the building operator how to sustain efficient operation implement capital improvements

Investigation
Determine how systems are supposed to operate, monitor how they operate, and prepare a prioritized list of the operating opps.

Implementation
Implement opportunities and verify proper operation.

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Planning Phase
Planning Phase
Assess BAS capabilities, potential opportunities, and Investigation approach.

Operating Phase

Investigation

Implementation

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Planning Phase
Kick-off meeting Obtain building data Benchmark performance (EUI comparisons) Review building operational issues Quantify range of potential savings Develop RCx Plan
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Benchmarking
Building Based:
Annual Utility Consumption from Billing Calculate EUI (energy use per SF) Compare to databases available: SIC, NAICS, CalArch, EIA, others

Use EUI to identify Retro-Cx potential and best candidates for Retro-Cx Consider any unique differences in your building systems or equipment as compared to typical buildings in the benchmark database
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Benchmark Example Natural Gas High Usage

Normalized Monthly Natural Gas Use- CH 1
10,000 9,000 8,000 Natural Gas (Therms) 7,000 6,000 5,000 4,000 3,000 2,000 1,000 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2002 2003 2004

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Benchmark Example Natural Gas Lower Usage

Normalized Monthly Natural Gas Use - CH 2
7,000 6,000 5,000 4,000 3,000 2,000 1,000 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2002 2003 2004

Natural Gas (Therms)

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Benchmarking Example
Building Floor Area (ft2) 126,972 110,286 CH 1 CH 2 Annual Electricity Use (kWh/yr) 2,435,239 1,473,933 Ann. Peak Electrical Demand (kW) 605 355 Annual Natural Gas Use (therms/yr) 78,246 47,934 Annual Electricity Costs ($) $308,081 $188,376 Annual Natural Gas Costs ($) $51,997 $33,762 Total Utility Costs ($) $360,078 $222,138

Annual Utility Consumption Data

Building Peak Annual Electrical Demand W/ft2 4.8 3.2 Electricity EUI (kBtu/ft2) 65.4 45.6 Electricity EUI (kWh/ft2) 19.2 13.4 Natural Gas EUI (kBtu/ft2) 61.6 43.5 Natural Gas EUI (therms/ft2) 0.616 0.435 Total EUI (kBtu/ft2) 127.1 89.1

CH 1 CH 2

Energy Use Index (kBtu/SF-year)

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Benchmarking Energy Use Index

160 Natural Gas EUI 140 120 103 EUI (kBtu/SF) 100 80 67 60 40 20 0 CM CH SM CH BH CH ML CH EM CH EL CH WH CH DN CH BL CH PL HQ 56 29 22 64 35 38 55 65 50 60 69 46 79 39 50 76 ` 26 105 62 39 42 44 102 Electricity EUI 127 108 89 139

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Benchmark Example Benchmark Against Database

CAL-ARCH DATABASE: Your whole building EUI is 127 kBtu/ft2-yr, which is higher than 92 % of comparison buildings shown. http://poet.lbl.gov/cal-arch/ OTHER DATABASES: Energy Star (EPA) Commercial Buildings Energy Consumption Survey (CBECS)

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RCx Plan - Purpose

Identify the approach in the Investigation Phase
Building Issues: Energy Usage Comfort Indoor Air Quality Noise Approach: Controls/Trending Design Maintenance Issues TAB

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Investigation Phase
Planning Phase Operating Phase

Investigation
Determine how systems are supposed to operate, measure and monitor how they operate, and prepare a prioritized list of the operating opportunities.

Implementation

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Investigation Phase
What is the equipment actually doing? Validate the direct digital control (DDC) system Trend system points Document conditions Identify changes to setpoints, schedules, & sequences and cost/benefits
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Evaluate Trend Data

Mountain America Credit Union
180.0 Cooling tower unable to maintain setpoint at full fan speed. Condenser Water maintianed at 70F 160.0 80.0 90.0

140.0
Current (Amps); OA Temp (F); RH (%)

70.0
CHW Supply-Return Temps (F)

120.0

60.0

100.0 System operates 6 am to 6 pm weekdays and 6 am to 1 pm Saturday 80.0

50.0

40.0

60.0

30.0

40.0

Cooling tower fans cycle between high and low speeds

20.0 Chilled Water maintianed at 50F 10.0

20.0

0.0 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 12:00 12:00 12:00 12:00 12:00 12:00 12:00 12:00 0:00

0.0

OA Temp (*F) Cooling Tower Fan #2 East (Amps) Cond Water Supply Temperature (*F)

Wet Bulb Temp (*F) Chilled Water Supply Temperature (*F) 22 Cond Water Return Temperature (*F)

Chiller Current (Amps) Chilled Water Return Temperature (*F)

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Investigation: DDC vs. Pneumatics

Can you RCx pneumatics? DDC Trending analysis Pneumatics Point to point verification, calibration Look for the signs
Disconnected linkages, actuators Inspect pressure gauges Review condition of control air Look at compressor station Regular PM program?
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Investigation Phase
Identify broken subsystems and equipment repair if needed for testing Perform TAB measurements (system level) Perform updated HVAC load study Identify opportunities for implementation
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Investigation Phase
Investigation report documents the retro-commissioning effort As-found conditions Adjustments or repairs made to systems (if any) Results of evaluation and Implementation plan Implementation costs and savings estimated Remaining issues that could not be resolved without upgrade-repair-replacement project Identify any capital projects to address current operational needs or correct problems Provide budget cost estimate for more capital intensive projects
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Implementation Phase
Planning Phase Operating Phase

Investigation

Implementation
Implement opportunities and verify proper operation

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Implementation Phase
Implement recommended opportunities and correct operational deficiencies to achieve improved performance and energy savings Performed by:
Internal maintenance staff Program manager, controls, mechanical, service, TAB, electrical contractor
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Implementation Phase - Verification

Verify modifications are in place Perform functional tests to assure modifications are operating as designed Trend performance to verify energy savings

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Verify Modifications Hot Deck Reset Temperature Control

Santa Monica Courthouse Hot Deck Reset AH-1 (11/28-05 to 12/1/05) 120 110

Hot Deck Temperature (Deg F)

100

90

80

Hot water system enabled

70

60 40 45 50 55 60 65 70 75 80 Outsid Air Temperature (Deg F)

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Track System Level Metrics Simultaneous Heating and Cooling

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Operating Phase
Planning Phase Operating Phase
Report operating improvements made and train the building operators how to sustain efficient operation implement capital improvements

Investigation

Implementation

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Operating Phase
Provide on-site training how is the building suppose to operate to sustain improvements Update O&M data Document setpoints and settings for systems
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Sustaining Improvements Continuous Cx

Track monthly building energy use
Compare similar months, different years Compare energy usage vs. OAT metric

Sub-meter major HVAC systems if possible

Cooling plant, heating plant, ventilation fans

Verify operation of energy conservation strategies

Track equipment run times (schedules) Track temperatures against set points
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Operation Phase - Verification

Overall Performance Comparison
250 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 12:00 AM 12:00 AM 12:00 AM 12:00 AM 12:00 AM 12:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM 12:00 PM 12:00 PM 12:00 PM 12:00 PM 12:00 PM 6:00 PM 6:00 PM 6:00 PM 6:00 PM 6:00 PM 125 120 115 110 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 12:00 AM Significant Demand and Overall Energy Reduction during similar load periods.

Overall Reduction of Base Load

12:00 AM

6:00 AM

6:00 AM

12:00 PM

12:00 PM

Time kW-2005 kW-2004 OAT-2005 OAT-2004

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6:00 PM

6:00 PM

Outside Air Temperature

kW

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Verify Energy Conservation Strategies

Space Temperatures WHAT YOU SEE

Scheduled Start/Stop Control Ventilation Control Chiller Sequencing Fan Speed Control Simultaneous Heating & Cooling
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WHAT YOU DONT SEE

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Typical Retro-Cx Project Timeline

Planning Investigation Implementation Verification 4 to 6 weeks 12 to 24 weeks 8 to 16 weeks 4 to 8 weeks

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Retro-Commissioning Findings

Top 10 HVAC Opportunities Found

10. Verify lighting controls schedules/effectiveness 9. Terminal unit tune-ups dampers & valves 8. Improve clg. tower sequencing/lower cond. wtr. temps 7. Improve chiller sequencing 6. Return VFDs to variable speed operation 5. Optimize supply air static pressure set points 4. Ensure proper ventilation airflow rate 3. Optimize/restore economizer operation 2. Implement reset schedules to eliminate simultaneous heating and cooling 1. Turn off equipment when not needed (Scheduled S/S)
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Top 5 Gas Opportunities

5. Improve boiler efficiency (tune-up or replace) 4. Implement aggressive air and water temperature reset strategies (HWS vs OA, MAT vs RAT, night setbacks, space temperatures) 3. Tune-up terminal units to eliminate simultaneous heating and cooling (valve leakage) 2. Optimum start/stop vs. scheduled start/stop (close OSA!! let Building coast to end of day) 1. Turn off heating plant when not needed (Scheduled S/S)
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PreFx Phase Controls Checkout

Typical Point to Point Findings: Sensors out of calibration Inoperative dampers (pneumatic control, transducers, actuators, linkages, dampers) Minimum OA damper settings Inoperative control valves Inoperative CHW/HW control valves Inoperative variable frequency drives (VFDs)
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PreFx Phase Air/Water TAB

Typical TAB Findings: Inadequate supply/return fan capacity Duct leakage / Duct obstructions Static pressure set points Maintenance Issues: Dirty filters/broken fan belts Terminal unit issues:
Thermostats out of calibration Reheat valves stuck or leaking by Inoperative damper actuators Air flow at terminal unit outside acceptable tolerances
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Example RCx Process

Building Issues (Interview): Difficult to maintain comfort interior zones (no reheat) versus exterior zones (reheat) Source of many hot complaints Design issue?? Point to Point Analysis: Chilled water valve stuck open on AHU-3 Supply air temperature maintained at 52F Noted as deficiency during PreFx Phase
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Example RCx Process (cont.)

Test and Balance: Could not achieve design air flow at zone level Functional Test Results: Bad duct pressure transmitter AHU VFD actually controlling to 0.6, instead of 1.2 Chilled water valve (AHU-3) connected to main air (20 psi), branch line bypassed

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Example RCx Process (cont.)

Implementation: Put CHW valve back on branch pressure control Replaced duct pressure sensor transmitter Performed test and balance to design conditions Restored outside air economizer capability Implemented discharge air temp. reset strategy
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Example RCx Process (cont.)

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Indicators of HVAC Opportunities

Changes to operating sequences Deferred basic maintenance Complex controls beyond O&M staff control Lack of system documentation Comfort complaints (hot or cold calls) Interim fixes to respond to localized requests Rising energy consumption demand (kW) or consumption (kWh) check EUI!!
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Economic Benefits
Existing Buildings Study*: 59 Buildings $0.26/sf-yr median normalized energy cost savings 0.7 years median payback * The CostCost-Effectiveness of Commercial Buildings Commissioning A MetaMeta-

Analysis of Existing Buildings and New Construction in the United United States, Nov 23, 2004 Lawrence Berkeley National Laboratory, Portland Energy Conservation Inc., Energy Systems LaboratoryLaboratory-Texas A&M University

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Benefits of HVAC Tune Ups

Cost depends on systems selected, size of building, type of building Budgetary estimates:
RCx from $0.30 to $0.70 per SF depending on scope of services required, size & type of building

ROI & Payback Excellent (<1 yr typical) Energy savings typically 5 to 15% Existing buildings account for over 95% of building SF most operate inefficiently ACEEE 2003 Study RCx 2nd best savings potential out of 38 evaluated processes!!! What is the cost of loss of comfort resulting in loss of productivity in poor building environment?
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Example Resources
Portland Energy Conservation Inc www.peci.org Building Commissioning Association, www.bcxa.org Practical Guide to Commissioning Existing Buildings, Haasl & Sharp, 1999, ateam.lbl.gov/mv/docs/RetroCommissioningGuide.pdf ASHRAE, Guideline 11-1996, The HVAC Commissioning Process, www.ashrae.org Continuous Commissioning Guidebook for Federal Energy Managers http://www.eere.energy.gov/femp/pdfs/ccg01_covers.pdf U.S. DOE / FEMP,www.eere.energy.gov/femp FEMP,www.eere.energy.gov/femp GSA Commissioning Handbook, www.gsa.gov CBECS, www.eia.doe.gov/emeu/cbecs Energy Star Portfolio Manager, www.energystar.gov/benchmark www.energystar.gov/benchmark
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Question & Answers

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Thank You!

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