identify and quantify mission-critical factors (how to …learning objectives • benefits of a...
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Identify and Quantify
Mission-Critical Factors
(How to Perform a Critical Audit)
Neil Maldeis , Energy Solutions Engineering Leader, Trane
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Learning Objectives
• Benefits of a critical system audit
• How to identify and quantify mission-critical
factors
• How to begin the journey to create a high
performance building with a critical system audit
• Tips to optimize your critical system audit
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Benefits of a Critical System Audit
• Providing a safer, healthier, more comfortable
environment
• Operating reliably with minimum unscheduled downtime
and fast recovery
• Maintaining performance within acceptable tolerances
throughout their lifespan
• Enhancing organization and occupant performance,
retaining/increasing in value and adding luster to the
organization’s brand and reputation
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Steps for Performing a Critical
System Audit • Assemble the right team of participants
• Define program objectives
• Understand mission-critical factors (identify and quantify)
• Gather relevant data and make comparisons
• Determine strategies and actions to meet objectives
• Measure results and determine program effectiveness
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• Assemble a team
• Define program objectives
– Reduce operating costs
– Increase operational performance
– Improve occupant comfort and safety
– Enhance employee productivity
– Achieve environmental certification
Build an energy management team with buy-in from key internal stakeholders,
including owners, managers and department heads
Conduct a Critical
Building Systems Audit
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Identify and Quantify Mission-Critical Factors
Consider the cost of a building failure on operations and stakeholders
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Example: School building
Identify and Quantify Mission-Critical Factors, cont’d.
Every building has unique factors to consider
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• Determine the current level of performance of key building systems: HVAC, lighting,
water, electrical, etc.
• Gather 3-5 years of actual energy cost data
• Use actual data to estimate annual cost of planned and unplanned maintenance
• Compare actual costs against industry averages and best-in-class performance
Gather Relevant Data and Make
Comparisons
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Gather Relevant Data and Make
Comparisons, cont’d
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Critical Area Equipment ID General Facility Equipment Information and Maintenance History
Critical Area Served ID Tag Manufacturer Model Number Serial Number Age
Maintenance Agreement(s) & Cost
Cooling System Equipment Type
Current Maintenance
Provider
Cost
1
2
3
4
5
6
7
8
Heating System
1
2
3
4
5
6
7
8
Pumps and Motors
1
2
3
4
5
6
7
8
Fans - Supply Air - Return air - Cooling tower etc.
1
2
3
4
5
6
7
8
Air Handling Equipment
1
2
3
4
5
6
7
8
Gather Relevant Data and Make
Comparisons, cont’d
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Determine Strategies and Actions
to Meet Objectives Major ECM Category ECM Type Technology/ECM Name Rating
Controls General/Special Upgrade to Direct Digital Control 100%
Industrial Compressed Air Implement Compressed Air Utility Management 100%
Water Reduce Use Install Low Flow/Use Fixtures 96%
Controls General/Special Retro/Recommission Controls for Optimizing Savings 94%
Controls General/Special Install Lab Hoods Control - Flow Safe Lab Hoods 94%
Supply Side Management Manage Energy Supply Change Regulated Utility Rate/Tariff 94%
Water Smart Metering Install Smart Meters & software -- for Billing & Accuracy 94%
Electrical Lighting Install Lighting Controls 92%
Electrical Lighting Replace T-8s for HiBays with T5s 92%
Plant Boilers Install Tankless/Instantanious Water Heaters 92%
Supply Side Management Manage Energy Supply Change to Interruptible Rates and Use Electric Generators 92%
Architectural Envelope Install Weather-Stripping 92%
Electrical Lighting Upgrade Fluorescent Fixtures w/ T8 or T5 Lamps and Electronic Ballasts 92%
Electrical Lighting Retrofit Incandescent Lamps w/ Compact Fluorescent Lamps 92%
Electrical Lighting Replace Exit Sign w/new LED Fixture 92%
Plant Boilers Adjust Burner as Regular Maintenance 92%
HVAC (Building/ Non-Plant) Unit Upgrade Convert CV to VAV 88%
HVAC (Building/ Non-Plant) Unit Upgrade Convert Dual Duct to VAV 88%
Electrical Lighting Replace HID HiBay fixtures with T5s or T8s 86%
Electrical Lighting Add LED night lights in halls 86%
Architectural Roof New Construction with Green Roofs (Plants) 85%
Plant
Water Source Heat Pump
Systems Install Water Source Heat Pump System 83%
Plant Motors/Pumping Install VFD/VSDs for Pumps 81%
Controls Resetting Reduce Outdoor Air To Design Level 78%
Controls Resetting CO2-Based Demand-Controlled Ventilation 78%
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“Re-commissioning” has become a mainstream concept
• Many buildings fail to live up to standards
their designers envisioned – even when
new
• Most buildings “drift” from original
parameters and perform less efficiently
as their functions change, equipment
wears and controls strategies deviate
from original design intentions
A disciplined re-commissioning project typically yields 10 - 20% energy savings
Determine Strategies and Actions to
Meet Objectives, cont’d
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Determine Strategies and Actions to
Meet Objectives, cont’d
Air handling systems (HVAC)
• Temperature setup/setback
• Sensors that are out of calibration, especially OA sensors
• Synchronizing the mechanical equipment with building
occupancy
• Economizers that haven’t been maintained
• Discharge air reset
• Static pressure reset
• Demand Control Ventilation
• Dirty condenser and evaporator coils and filters
Top Control Strategy Improvements
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Chilled Water Systems
• Chilled and condenser water reset
• Optimal start/stop of major equipment
• Cooling tower optimization
• Fan and pump speed drives
Heating Systems
• Boiler hot water reset
Determine Strategies and Actions to
Meet Objectives, cont’d Top Control Strategy Improvements – cont.
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Select improvement actions Typical savings
Lighting—implement solutions for maximum energy savings 10–15 %
Building Automation/Controls 5–15%
HVAC upgrade—replace aging equipment with state-of-the-art models 5–15%
Plant upgrade — replace chillers/boilers with higher efficiency models 5–15%
Pumps and motors — replace with higher efficiency models 5–15%
Comprehensive energy savings projects — improvements in all of the
above areas. Lighting solutions may account for as much as half of the savings in a
comprehensive project.
20–30%
Building performance improvements offer solid return on investment
Measure Results and Determine
Program Effectiveness
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Building performance improvements increase energy efficiency
Measure Results and Determine
Program Effectiveness, cont’d
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• Understand the mission, purpose and
objectives of your organization and its
buildings
• Assemble the right team
• Define your objectives
• Identify gaps and key improvement
opportunities
• Create an improvement plan and take
action
• Measure the results for effectiveness
Energy efficiency
& environmental
performance are
critical
Organizational
performance and
productivity drive
value, ROI
Effective service
strategy
maintains
lifecycle
performance
Keys to Success
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QUESTIONS
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APPENDIX
CRITICAL AUDIT WORK SHEETS
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Critical Area Equipment ID General Facility Equipment Information and Maintenance History
Critical Area Served ID Tag Manufacturer Model Number Serial Number Age
Maintenance Agreement(s) & Cost
Cooling System Equipment Type
Current Maintenance
Provider
Cost
1
2
3
4
5
6
7
8
Heating System
1
2
3
4
5
6
7
8
Pumps and Motors
1
2
3
4
5
6
7
8
Fans - Supply Air - Return air - Cooling tower etc.
1
2
3
4
5
6
7
8
Air Handling Equipment
1
2
3
4
5
6
7
8
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Available Building Documents
General
1 Obtain Drawings
Previous Audits or future system Planning
1
Have critical areas and critical systems audits have been conducted previously?
2 Can I have a copy for our records?
3 Facility changes planned in near future?
4 Operational changes planned in near future?
5 Any equipment in need of repair, upgrade or replacement?
6 Any unplanned equipment outages/failures in past 12-mont
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Mechanical System
Enter
Yes, No
or N/A
Mechanical Cooling System (Various) 1 Are condenser pressures & temperatures correct vs specification?
2 Are evaporator pressures & temperatures correct vs Specification?
3 Are obvious refrigerant leaks and surging detected?
4 Are sensors installed correctly?
5 Have sensors been calibrated in past 12 months?
6 Are safeties, interlocks & alarms functioning correctly?
7 Any excessive compressor or motor noise, vibration heat emission observed
Cooling Towers (As applicable) 1 Fan bearing any excessive noise, vibration heat emission observed
2 Fan Motor bearings any excessive noise, vibration or heat emission observed
3 Gearbox assessed any excessive noise, vibration or heat emission observed
Condenser Water Pumps (As applicable) 1 Any excessive noise, vibration heat emission observed
2 Coupling alignment (as applicable) satisfactory - any excessive noise, vibration heat emission observed
3 Seal Condition (as applicable) any excessive water leaks
4 Bearing status, any noise or overheating observed
Chilled Water Pumps (As applicable) 1 Any excessive noise, vibration heat emission observed
2 Coupling alignment (as applicable) satisfactory - any excessive noise, vibration heat emission observed
3 Seal Condition (as applicable) any excessive water leaks
4 Bearing status, any noise or overheating observed
Electrical Control Panel, Starter or MCC Panel(s)* (Recommend to be completed by certified electrician)
1 Any excessive heat emission observed
2 Any Terminal corrosion observed
3 Any excessive contactor or relay chatter observed
4 Any excessive transformer hum or vibration detected and/or heat emission
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Controls Systems
Enter
Yes, No
or N/A
Conformance to Specification
1 Is Control system in your facility latest version
2 Are areas with special HVAC requirements monitored in accordance with engineering design temp set points, alarm set points etc.
3 As-built drawings, schematics and P&ID's up to date?
4 Spare parts on hand per recommendation?
5 Correct software and revision level?
6 Are there back up procedure for software and graphics?
7 Is eqiuipment commissioning up to date?
Workstation & Building Controllers
1 Critical alarms monitored remotely?
2 Are all monitored data points in specification?
3 Are data points monitored remotely
4 Are system set point changes logged and reviewed at least weekly?
5 Programming matches sequence of operations?
6 Does system have electrical outage ride-through capability - is there UPS capability
7 Operation of control sensors and devices monitored 24/7/365
8 Software changes controlled, authorization codes used and logged?
9 Is there a written procedure for addressing alarm logs?
10 Are all manual overrides reviewed at least weekly by the supervisor?
Programmable and Configurable Controllers
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1 Unit graphics and custom reports functional?
2 Programming matches sequence of operations?
3 Are all manual overrides reviewed at least weekly by the supervisor?
4 Sensor readings are within tolerance?
5 Operation of control sensors and devices monitored 24/7/365
6 Are standalone control devices calibrated?
7 Are trends set up and reviewed periodically?
8 Are all set points routinely verified?
Unit Controllers (as applicable)
1 Is the alarm log routinely investigated?
2 Are unit graphics and custom reports functional?
3 Are all manual overrides reviewed at least weekly by the supervisor?
4 Are sensor readings are within tolerance?
5 Are operation of control sensors and devices inspected at least quarterly?
6 Are the procedures for calibration of standalone control devices routinely monitored?
7 Are trends set up reviewed periodically?
8 Are test points verified?
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Maintenance Practices
Enter
Yes, No or N/A
Areas with Special HVAC Requirements
1 HVAC filters properly installed and maintained to prevent air leakages and dust overloads?
2 HEPA filter units checked? If Applicable
3 Clean area performance verified by appropriate particle testing?
4 Back up / emergency power HVAC available to sustain systems operation?
5 Areas with special ventilation, filtration, or pressurization requirements monitored?
6 Air duct flow outputs measured to ensure proper function?
7 Are air duct grills scheduled for cleaning during unoccupied times?
Fresh Air Intakes
1 Fresh air intakes monitored for bird nesting or standing water etc.?
2 Bird screens in good repair?
Outside Air Dampers
1 Are OAD operation acceptable?
Filters
1 Are correct filters installed compared to design specifications?
2 Are the pressure drops across filters OK? (Compared to manufacturer's recommendations.)?
3 No detrimental =contaminants visible?
Humidifiers (if applicable)
1 Nozzles appear clean and functional?
2 Are the pans clean with no visible overflow?
3 Are the drains properly trapped?
4 Is the biocide treatment working properly?
Cooling Coils
1 Is there sufficient inspection access?
2 Do the Cooling coils appear to be clean?
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Condensate drip pans
1 No indication of condensation problems?
2 No visible growth (e.g., slime)?
3 Drains and traps clear, working?
Mist Eliminators (if applicable)
1 Clean, straight, no carryover?
Supply fans
1 Fan blades appear to be clean?
2 Belt guards appear to be properly installed?
3 Belt tension appears to be correct?
4 Motor and Fan vibration levels seem normal?
5 There appear to be no corrosion problems?
Heating Coil
1 There is clear unobstructed inspection access?
2 Hearing coils appear Clean?
Room partitions
1 Airflow within air partitions appears to be OK?
Return fans
1 Fan blades appear to be clean?
2 Belt guards appear to be properly installed?
3 Belt tension appears to be correct?
4 Motor and Fan vibration levels seem normal?
5 There appear to be no corrosion problems?
Preventive maintenance
1 Are there sufficient Spare parts inventoried?
2 Are there sufficient and proper spare air filters?
3 Are control drawing posted?
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4 Are utility Management Plan, Preventive Maintenance program up to date?
Boilers (if applicable)
1 Are Flues airtight?
2 Is the purge cycle working properly?
3 Do door gaskets appear to be tight?
4 Is the fuel system tight, no leaks?
Cooling Towers
1 Is the tower sump clean?
2 Are any leaks or overflows evident?
3 Are eliminators working, no carryover?
4 Is there any slime or algae apparent?
5 Is the biocide treatment properly functional?
Chillers
1 Are chiller condenser approach temperatures correct vs chiller specification?
2 Are chiller evaporator approach temperatures correct vs chiller Specification?
3 Are there any observed refrigerant leaks?
4 Does the purge cycle operate normally?
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Utility Diversity, Risk & Redundancy (Data Center Example)
Enter
Yes, No
or N/A
HVAC Equipment Utility Supply Diversity
1
Is there redundancy designed into the cooling system, with redundant isolation valves or airside dampers?
2
Power is supplied to cooling system including all motors pumps and fans from two separately derived electrical sources?
3
Power is supplied to redundant / parallel air handling units from two separately derived electrical sources/
4 Controllers / BCU's on UPS with redundant electrical sources?
5 Primary / Standby AHU motors have separately derived electrical sources ?
6
Air flows, pressure, temperature and humidity relationships are considered in designing diversity in normal, stand by and emergency power?
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Equipment & System Vulnerability Risk Safety
Enter
Yes, No
or N/A
Risk mitigation
1 Can critical areas be served from other units if major system is disabled?
2 Is the air supply to critical areas compartmentalized?
3 Are there emergency shut down & start up procedures
4 Are the emergency start up procedures maintained & current
5 Is facility staff fully trained in these procedures
Redundancy
Enter
Yes, No
or N/A
HVAC Equipment Redundancy
1 Critical area air handling units have fan redundancy?
2 Quality of drain pan under air handling units satisfactory?
3 Is there sufficient Space heating redundancy?
4 Cooling towers have at minimum redundancy?
5 Chillers have at least N+1 redundancy?
6 Condenser water pumps have N+1 redundancy?
7 Chilled water pump have N+1 redundancy?