Can You Afford Not To Retro-Commission Your Facility In These Lean Times? Wednesday, October 3, :00pm 2:15pm

Transcription

1 Can You Afford Not To Retro-Commission Your Facility In These Lean Times? Wednesday, October 3, :00pm 2:15pm

2 Presenters Bruce Pitts Len Rozek Mark Howe

3 Learning Objectives Learn how and see examples of how to build a viable roadmap in your facility for EBCx and sell it to the C-Suite. Gain an understanding of the BCA / ASHE EBCx process. Learn how to create the right EBCx team to forge sustainable. Learn how to generate your EBCx story so that it has high impact to the CFO.

4 Assertion Commissioning: the cure for what ails you. Today you will hear how EBCx works, see a realworld case of EBCx benefits and savings in action, and hear from an Owner s representative how to create the business case for EBCx.

5 Life Cycle of Systems Installation testing Maintenance and repairs are performed during operational life At the end of useful life, breakdowns and failures occur

6 Background Historical Drivers of Commissioning (Cx) activities o Owners desire quality and performance o Some codes and regulation require Cx o LEED requires early involvement of Cx Authority o Variety of factors in construction phase continue to influence thoroughness of Cx Hospital Accreditation requires documentation of systems readiness and reliability

7 Background Maintenance programs find and repair building items prior to interrupting the building operation Scopes vary from o o o o None Inspect only Check and Adjust Schedule downtime and perform repairs

8 Background Healthcare / Hospitals Data Centers Manufacturing Facilities Commerce Continuity Customer

9 Types of Commissioning New Building Commissioning Re-commissioning Existing Building Commissioning o o o ASHRAE, BCA and ASHE Utility Programs ESCO Contracts Continuous Commissioning These do not necessarily take a whole building approach These are holistic programs Healthcare guideline compartmentalizes retrocommissioning to an energy exercise

10 Existing Building Commissioning The Process Scoping and Planning Phase Investigation Phase Implementation Phase Turnover Phase Monitoring & Verification Phase The Building Commissioning Association has published an Existing Building Commissioning Best Practices a-e ef-dc1bf6c8f6af.pdf A copy can also be requested from the speakers.

11 Typical Current State The installing contractor will perform a point to point testing and checkout There is some form of commissioning required by the project Controls systems are calibrated, adjusted or repair at the component or unit level o Sensor or Actuator o Damper system o Air Handler or Chiller The project is completed and turned-over.

12 EBCx is Part of Every Process Project Transition Commissioning Project Construction Test and Balance Integrated Systems Testing Black out Operations and Maintenance Adjust and Calibrate Repair Refurbish Design and Bid Define scope Select components Approve Supplier Interim Drivers Life Cycle Replacement External Factors

13 The EBCx Program A holistic building evaluation, including maintenance and operational practices, as well as the value of potential capital improvements. o No- and low-cost measures bring quick returns. o Capital expenditures are defined and budgeted. o Baseline of actual facility usage, not theoretical. Should include a Measurement and Verification component to validate improvement measures. On-going commissioning contributes to savings persistence.

14 Getting in the Door Utility programs and incentives vary by region; check HCAHPS allocates premium of Medicare funding based on higher scores Can a holistic solution be found that enhances the patient experience? Don t let deferred maintenance snowball. Yes it s free to do nothing now, but when that bill comes due ESCO programs Expand an ESCO program to make it a complete, holistic EBCx plan.

15 Survey Show of hands: owners or operators of facilities Commissioning is an integral part of major construction projects Show participating in re-commissioning Why aren t the rest of you improving energy, life cycle, reliability, and patient and staff objectives?

16 IFMA ASHE Survey Hospitals often conduct patient surveys. We learned from this group that 83% also capture facility-related data from customers, patients and tenants.

17 Systems to Commission HVAC Air handling equipment chillers, boilers, cooling towers Hot Water Electrical Power quality, back-up power Life Safety Medical Gas Telecom/IT

18 Case Study: Site New England Campus Central Plant Gross Square Footage Campus 1.5M SF Conditioned Square Footage Campus 1.3M SF Multiple Buildings Offices, labs, and other mission-critical facilities Occupancy 95% assumption

19 Case Study: Equipment Central Plant Heating Plant HTHW: 5 boilers ranging from 15 MMBTUH to 40 MMBTUH Hot Water Distribution Primary / Variable Secondary / Variable Tertiary Chiller Plant 9 Centrifugal Chillers ranging from 610 ton to 2,000 ton Chilled Water Distribution Primary / Variable Secondary / Variable Tertiary Cooling Tower 7 induced draft and 2 forced draft Condenser Pumps Individual pump per chiller

20 Case Study: Site

21 ECM Simple Payback Measure Energy Savings Cost Simple Payback (Yrs) 1. Chiller Selection (OECM#4) $ 82,623 $ 26, CW Temp. Reduction (OECM#2) $ 1,136 $ 5, Tower VFD Optimization (OECM#3) $ 28,561 $ 21, C 4&5 and 8&9 CHW Pump VFD (OECM#5) $ 18,517 $ 133, Increase CHW temp to 44 $ 19,718 $ 14, Reduce Boiler Idle Temp. (OECM#6) $ 15,991 $ 15, $ 166,545 $ 217,

22 Chiller Plant Data Chiller Make Size (Tons) Year VFD Voltage CHW Pumps 1 Carrier NO hp 2 Carrier NO 480 w/ CH 1 3 Carrier NO 480 w/ CH 1 4 York 1, YES hp 5 York 1, YES hp 6 Carrier 2, NO HP 7 Carrier 2, NO 4160 w/ CH 6 8 York 2, NO hp 9 York 2, NO 4160 w/ CH 8

23 Cooling Tower Data Tower Make Size (Ton) Type VFD Fan Motors CW Pumps 1 BAC 812 Ind. Draft YES 2-25 hp 1-50 hp 2 BAC 812 Ind. Draft YES 2-25 hp 1-50 hp 3 BAC 812 Ind. Draft YES 2-25 hp 1-50 hp 4 BAC 1,874 Forced Draft YES 4-50 hp hp 5 BAC 1,874 Forced Draft YES 4-50 hp hp 6 BAC 2,500 Ind. Draft YES 4-25 hp hp 7 Ceramic 2,000 Ind. Draft YES 2-50 hp hp 8 EVAPCO 2,500 Ind. Draft YES 4-25 hp hp 9 EVAPCO 2,500 Ind. Draft YES 4-25 hp hp

24 Case Study: Historical Operation

25 Case Study: ECM #4

26 Case Study: ECM #4

27 Case Study: ECM #4

28 Case Study: ECM #4

29 Case Study: ECM #4

30 Establishing Hours of Operation

31 Baselining of Actual Plant Operations

32 Proposed Optimized Chiller Staging

33 Operating Cost For Two 610 Ton Chillers * Chillers are operated only during extreme weather when OAT > 93 F. This occurs on average 20 hours per year. Assume this happens over two months (thus saving two months of peak demand charges) ** Assumes a $/kwh charge for the 10 hours of operation. *** Electric Savings minus the Generator operating costs.

34 Case Study: ECM #5

35 Case Study: ECM #5

36 Case Study: ECM #5

37 Case Study: ECM #5

38 Case Study: Capital Improvement

39 Case Study: Site

40 Case Study: Capital Improvement

41 Case Study ECM Summary Measure Energy Savings Cost Simple Payback (Yrs) 1. Chiller Selection (OECM#4) $ 82,623 $ 26, CW Temp. Reduction (OECM#2) $ 1,136 $ 5, Tower VFD Optimization (OECM#3) $ 28,561 $ 21, C 4&5 and 8&9 CHW Pump VFD (OECM#5) $ 18,517 $ 133, Increase CHW temp to 44 $ 19,718 $ 14, Reduce Boiler Idle Temp. (OECM#6) $ 15,991 $ 15,900 1 $ 166,545 $ 217,

42 Case Study ECM Financial Low No Cost Summary Total Cost $211,506 Simple Payback of investment in 1.3 years System Improvements Towers Total Cost $580,000 Payback in 24.3 years Intangible Carbon Reduction Reliability

43 The Owner s Perspective The value of EBCx is the holistic audit process to identify opportunities o System enhancements Life cycle or redundancy o Process and documentation changes o ROI Easy, low or no cost o Intangible benefits Sound reduction, aesthetics, employee morale Conduct review against corporate requirements o Payback o Life cycle replacement of equipment o Timing with other building improvements

44 EBCx Results Now What? Summary Expect unexpected findings Time to implement will be longer than expected Look for allies, stakeholders and required resources o Peers o Traditional relationships including other corporate departments such as procurement or business unit o New relationships such as corporate environmental or communications Tell the good story

45 Functional Elements Patient Experience Clean Quiet Comfortable Reliability Utility Management Life Safety Hazardous Substance Medical Equipment Maintenance Repairs Adjustments Cleaning Testing Energy Cost / Consumption Carbon Footprint Water and Sewer Waste Stream Diversion Mutual Benefit through Synergy

46 Combine Function Elements Controls systems are calibrated, adjusted or repaired at the component level Point to point testing and checkout Check functional operational sequences o Unit start-up, ramp-up of fan & response of VAV boxes o Economizer optimized for zones o Mechanical Cooling loading up & sequencing of chiller plants o Live transfer of generator loads Update support documentation and records o Sequence of control o Capacity Studies Use funding sources such as utility rebates

47 EBCx Program Benefits Increase in the performance of systems o Reliability and redundancy for critical process loads o System/controls optimization o Identifies deferred maintenance or malfunction Decrease or no change in maintenance costs Decrease in energy consumption (7-20%) Improved operator skill level Process documentation and record keeping Planning and budgeting horizon becomes more predictable

48 Create Money As we ve said, it is easiest to do nothing. Deferred maintenance is cheap, but is not necessarily a sustainable approach. Increasing the life of capital equipment improves the ROI of that equipment. Improving system operation (indoor air quality, temperature control) improves occupant satisfaction. Lowering current operating costs frees up funds for other cost centers. Use funding sources such as utility rebates

49 In order to understand others EBCx addresses and improves the Patient Experience / Satisfaction (PES) o CFO will be interested in the cost savings o Other C-suite executives support is based on PES

50 Tailor your Audience Include Maintenance Staff as well as Operations and Finance Recognize differing priorities in these groups Encourage a cross-departmental approach to savings and improvement; capital costs can result in maintenance savings. This means going high in the organization to find the focal point of overall facility cost reduction priority.

51 Craft Your Elevator Pitch 1. bring in outside funding, rebates, other financial incentives 2. a holistic program identifying no/low cost ECMs and FIMs 3. other capital improvements providing additional benefit, such as redundancy, life cycle replacement extension, TIs

52 That s a Wrap Did Commissioning Fix Everything? An EBCx program can provide: o o Quick wins (no and low-cost improvements that can be implemented in a short time frame) to a facility o A plan for future opportunities. o Don t forget you can ameliorate the cost of the capital projects with the low-cost findings. Provides frame work to implement a holistic program

53 Audience Discussion Project Transition Commissioning Project Construction Test and Balance Integrated Systems Testing Black out Operations and Maintenance Adjust and Calibrate Repair Refurbish Design and Bid Define scope Select components Approve Supplier Interim Drivers Life Cycle Replacement External Factors

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