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Energy Audit report for Fitness and Recreation center (Gym)

Department of Mechanical Engg, Purdue University Calumet Page 2

Executive Summary

As part of an initiative to reduce energy cost and consumption, Purdue University

Calumet (PUC) has secured the services of School of Engineering, Maths & Science (EMS)

to perform an energy audit for their Fitness and Recreation center (Gym) in an effort to

develop comprehensive Energy Conservation and Retrofit Measures (ECRMs).

EMSs energy audit team visited the gym on February 2nd, 2012. As a result of the site

visits and evaluation of the historical energy usage of the facility, EMS was successful in

identifying various activities of the gym and building system components that present

feasible opportunities for energy savings measures.

EMS has also evaluated the potential for electrical energy usage. Specifically, the use

of Metal Halide lighting systems which can be replaced with Induction Fluorescent lighting

systems which provides better lighting and are maintenance free, the average life hours is

estimated to be 1,00,000 hours and saves up to 67% energy savings over HPS and metal

halide.

The team has also come up with an idea to add a lining to the exterior metal doors inorder to prevent heat loss from the sides of the door which was found form the images from

IR camera. We have recommended to go with 1/8th inch thick thermal sealing adhesive tapes

for the side areas of the doors and transom seal for the bottom portion of the doors and saves

up to 46% of the heat lost from doors, thereby saving up to 15% of the energy.

It was also found that by updating the thermostat we will be able to control the

temperature of the gymnasium in a better way and will be able to remove the use of

compressor.

In addition, EMS has come up with proposals to introduce Economizer for the boiler

which increases the boiler efficiency which will also be best energy cost saving. A generally

accepted "rule of thumb" is that about 5% of boiler input capacity can be recovered with a

properly sized economizer. It has also been noticed from the IR images of the boiler shows

heat escape from the boiler and it is recommended to replace the boiler lining so as to decease

the heat lost from the boiler.


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Not all ECRMs identified as a result of the energy audit are recommended. We have

chosen the ECRMs which are economically feasible to be recommended to the University for

Implementation. The feasibility of each ECRM was measured through a simple payback

analysis. The simple payback period was determined after establishing Engineers Opinion of

Probable Construction Cost estimates, O&M estimates, projected annual energy savings

estimates, and the potential value of New Jersey Clean Energy rebates, or Renewable Energy

Credits, if applicable. ECRMs with a payback period of 20 years or less are recommended.

Recommended ECRMs

The following table, Table ES-1, presents the ranking of recommended ECRMs

identified for treatment processes and equipment and various building system components at

the wastewater and water treatment and pumping facilities. Additional ECRMs were

identified and evaluated, as discussed in Section 4; however, were not recommended due to

longer payback periods. Table ES-1 includes the Engineers Opinion of Probable

Construction Cost, projected annual energy cost savings, projected annual energy usage

savings, and total simple payback period for each recommended ECRM. The ECRMs are

ranked based on their simple payback period.

Ranking Type Initial cost diff. Operating cost savings Simple payback

1 Lighting 30,000 2900 10.3 yrs.

2 Door Insulation 500 275 1.8 yrs.

3 Economizer 2850 1150 2.5 yrs.

4 Thermostat 90 90 1.0 yrs.

Table shows the ranking of different ECOs recommended from energy audit


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Section 1: Introduction

1.1Purpose of the energy audit reportAs part of an initiative to reduce energy cost and consumption, Purdue University

Calumet (PUC) has secured the services of School of Engineering, Maths & Science (EMS) to

perform an energy audit for their Fitness and Recreation center (Gym) in an effort to develop

comprehensive energy conservation initiatives.

The performance of an Energy Audit requires a coordinated phased approach to

identify, evaluate and recommend energy conservation and retrofit measures (ECRM). The

various phases conducted under this Energy Audit included the following:

Gather preliminary data on all facilities; Facility inspection; Identify and evaluate potential ECRMs and evaluate renewable/distributed energy

Measures.

Develop the energy audit report.

Figure 1-1 is a schematic representation of the phases utilized by CDM to prepare the Energy

Audit Report.

Fig: 1 shows the general steps followed during energy audit

Gather primary data

Energy Bills

FacilityDescription

FacilityOperating hours

Detailedequipment lists

Facility Inspection

Lighting Building Shell Boiler room

HVAC systems Hot air

distributionsystems

Electricalsupply systems

Hot aircirculationsystem

Identifying andevaluating

Energy AuditReport


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Section 2: Facility description

2.1 The Fitness and Recreation centerThe Purdue Calumet Fitness & Recreation Center is home to the Peregrine volleyball

and mens and womens basketball teams. The Fitness & Rec Center also houses offices

and conference rooms for PUC athletics along with two racquetball courts, locker rooms,

a running track. The gym floor was renovated in the summer of 2011 with a complete

redesign and the addition of several new features due to rule changes in the NAIA and the

NCAA.

The universitys Fitness Center, under the direction of John Bobalik, is also housed in

the building. The Fitness Center is a comprehensive, multi-dimensional physical fitness

training facility designed to service Purdue Calumet students, faculty, staff and people

from the surrounding communities.

Purdue Calumet announced a ground-breaking agreement with the City of Hammond

in March 2011 to develop Dowling Park (located just north of I80-94 on Kennedy

Avenue) into a comprehensive outdoor sports complex for both Peregrine Athletics and

the Hammonds Parks and Recreation Department. The new athletic facility will house

the playing fields for the Black and Golds baseball, mens & womens soccer, softball

and mens & womens tennis teams.

2.2 Size, construction, facility and hours of operationThe objective of the energy audit is to identify energy conservation and retrofit

measures to reduce energy usage and to develop an economic basis to financially validate

the planning and implementation of identified energy conservation and retrofit measures.


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Section 3:Energy bill analysis for Fitness & Recreation Center (Gym)

Month kWh used kWh cost ($) Demand(kW)

Demand cost($)

Total cost($)

March 2011 450 1468 25 178 1646April 2011 444 1448 20 142 1590May 2011 436 1422 18 128 1550June 2011 445 1451 19 135 1586July 2011 449 1465 17 121 1586August 2011 421 1373 16 114 1487September 2011 439 1432 16 114 1546October 2011 450 1468 16 114 1582November 2011 450 1468 18 128 1596December 2011 451 1471 19 135 1606

January 2012 449 1465 20 142 1607February 2012 448 1461 22 156 1617

Table 3.1 shows the energy bill analysis of gymnasium from March 2011 to February

2012.

Note:

1. No. of units = 632. Watt per unit = 800W3. Price per kilo watt hour = $0.06732 (Approx)4. Demand cost for per kilo watt hour = $7.1 (Approx)5. The area is heated in winter and is not cooled in summer.6. The formula for calculating the cost of running a device

Cost of electricity = Wattage * Hours used / 1000 * price per kWh


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Fig 3.1 shows the bar graph of kWh vs. months

Fig 3.2 shows the bar graph of total cost vs. months

405

410

415

420

425

430

435440

445

450

455

kWh demand Vs Months

kWh used

1400

1450

1500

1550

1600

1650

Total cost ($) Vs Months

Total cost ($)


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Fig 3.1 shows the bar graph of demand kW vs. months

0

5

10

15

20

25

Demand (kW) Vs Months

Demand (kW)


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Section 4: Utility rate structure

Many utilities are starting to plan for changes in their utility rates for 2006. The

following information is presented in response to requests from readers to provide a summary

of the types of water rate structures most often used. This overview can be shared with

decision makers to help facilitate discussion regarding the most desirable rate structure for

your utility.

Flat Feeis a rate structure where all customers are charged the same fee, regardless of

the volume of water used. A flat fee does not take into account the cost of providing service

to various user classes or encourage reasonable water use through increased costs for

increased usage. A flat fee is simple and can provide stability through knowing the revenue

that will be generated per household.

Constant Block (Uniform Rates) is a structure that has a constant unit price for all

metered volumetric units of water consumed on a year-round basis. It differs from a flat fee

in that it requires metered service. Constant block rates are appropriate when the cost of

providing the service is generally the same across all user classes, although multiple constant

blocks can be utilized for multiple user classes. Constant block rates provide some stability

for utilities and encourage conservation because the costumer bills vary with water usage.

Declining Block Ratesis a rate structure in which the unit price of each succeedingblock of usage is charged at a lower unit rate than the previous block(s). Declining block

rates are designed to recover the costs of serving different classes of costumers while

maintaining reasonable equity among the costumer classes. Declining block rates assume

that customers that have a higher demand also have a more predictable peak demand than do

smaller customers. Thus they receive a discounted rate for the higher volumes that they use.

Declining block rates do not, however, promote conservation, and many utilities are moving

away from this rate structure.

Increasing Block Ratesis a rate structure in which the unit price of each succeeding

block of usage is charged at a higher unit rate than the previous block(s). Increasing block

rates are designed to promote conservation. While this can be beneficial, it is also harder for

a utility to predict revenues from seasonal consumption. When the rate for additional usage

is high, costumers may cut usage, and the utility may experience reduced revenues.


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Section 5: Energy conservation opportunities

5.1: Listing of potential ECOs

Lighting Alternative

Induction Fluorescent lighting systems

Induction Canopy Light - 120 Watt

Wattage : 120 Voltage : 277 Bulb Type : 120W Bulb(s) Included : Yes Metal Halide Equal : 175 Watt Life Hours : 100,000 Lumens (Initial) : 9600

Long lifespan due to the lack of electrodes - between 65,000 and 100,000 hoursdepending on the lamp model

High power factor due to the low loss in high frequency electronic ballasts which arebetween 95% and 98% efficient

Minimal Lumen depreciation (declining light output with age) compared to otherlamp types as filament evaporation and depletion is absent

Instant-on and hot re-strike, unlike most conventional lamps used incommercial/industrial lighting applications (High Pressure Sodium and Metal

Halides)

Environmentally friendly as induction lamps use less energy, and generally use lessmercury per hour of operation that conventional lighting due to their long lifespan.The mercury is in a solid form and can be easily recovered if the lamp is broken, or

for recycling at end-of-life


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Real-Time Clock-keeps time during power failures & updates automatically fordaylight savings

Change/Check Reminders- alerts when you need to replace batteries, filters, or serviceis needed

Precise Comfort Control - +/- 1 degree Fahrenheit Programmable Fan Energy Star Rating 5 Year Warranty Touch Screen Interaction Up to 7 Day Programmability Permanent Memory Retention Adaptive Intelligent Recovery Dual Powered - Battery and Hardwire Takes 3 AAA Batteries

Introducing Economizer

How They Work

Boiler stack economizers are simply heat exchangers with hot flue gas on one side and water

on the other. Or, in direct contact condensing units, the make-up water is in direct contact

with the flue gases.

Economizers must be sized for the volume of flue gas, its temperature, the maximum

pressure drop allowed through the stack, what kind of fuel is used in the boiler, and how

much energy needs to be recovered. Economizers designed for natural gas only, would likely

plug-up if installed on a coal boiler and would face increased risk of corrosion if installed on

an oil-fired boiler. Some units are designed to keep the flue gases above condensationtemperature, and others are made of materials that resist the corrosive effect of condensed

flue gases.


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Fig 5.1 shows the schematic representation of boiler with economizer

Economics

The savings potential is a function of how much heat can be recovered, which is a

function of how much cold water needs to be heated. A generally accepted "rule of

thumb" is that about 5% of boiler input capacity can be recovered with a properly

sized economizer.A higher percentage can be recovered with a Flue Gas Condenser, assuming there is

enough cold water to condense all of the flue gas that is available. Therefore, for 'ball

parking' purposes, start by comparing boiler input capacity with the need to heat

water.

Introducing Thermal Insulation

From the IR images we can find that heat lost from the corners od the metal doors due

to lack of insulation. A typical door 3 X 8 is 36 sq. ft. so 8 of the 4 6 wide MLV will coverit. 9 of the 4X1 foam will be needed.

You could use gaskets that are ordinary thermal sealing gasketing foam strips from

the hardware store, but far better results can be had if you use our Super Soundproofing 1/8

Thick Self-Adhesive Tape, because it is a closed cell material, will seal better and is much

more durable. It is a gray tape in widths of 1/4, 3/8 & 1/2 for door sealing. Apply strips on

top of each other to build up and close wide gaps.


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Remove the molding from around, the door and check the gap between the frame of

the door and the rough framing. Sliding doors have little or no thermal insulation qualities at

all and are best replaced. If its a glass patio door, you could cover part of it with a mat and

make a holding panel with mat attached to it to cover the door that moves when its shut.

Another option is to add another patio door with a new frame. This double door will block a

lot of heat escape by trapping air between the door panels. Commercially available thermal

proofing sliding glass doors can be had here.

Fig 5.2 shows the fitting of transom seal

Fig 5.3 shows the top view of the foam seal

fitting.

Some notes about our Door Sweep

(transom seal): (The part that should seal the

door bottom against sound and that fits on the

bottom of the door). A transom seal is usually

available from the hardware store that fits on

the floor across the doorway. Use this kind too,

if you have a huge gap. Try to get one with a

rubber flap. (Mechanical ones are expensive

and will eventually fail).

Fig 5.4 shows the front view of the door seals

Fig 5.5 shows the pictures from an IR camera the heat loss from indoor and outdoor doors


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The correct type of seal will not only help seal out heat lost but improve the doors

thermal rating. A seal is essential to properly thermal proof a door. The seal is a rubber loop,

cut to your door width size, modified by us with sealed ends for added performance in

creating a dead air space in the loop. Well cut this to an exact fit for the width of your door if

youll give us the measurement of the width of the door. You will also receive the proper

screws to mount it to your door, depending on whether its metal or wood. Only a

screwdriver and a few minutes is needed to install this very much needed attachment to block

sound from coming underneath your door.

5.2: Cost and savings analysis

Lighting ECOReplacing an existing 800W Metal halide lamp with a 120W Induction florescent lamp when

it burns out

Cost: The price remains the same for 50.4 kW and for 47.2 kW Power savings: 50.447.2 = 3.2 kW Lamp operates for 5400 hrs. per year and electricity cost is $0.06732 Savings = 3.2 * 5400 * 0.06732 = $1163.32/ yearType WATT Life

hrs.lumens No of

bulbsTotalkW

Costincl.

fixture

Total($)

Ann.hrs

LifeExpectancy

MetalHalide

800 16,000 60,000 63 50.4 295 18,585 5,400 3yrs

Inductionflorescent

120 100,000 9600 394 47.2 150 59,100 5,400 19 yrs.

Table 5.2.1 shows the comparison of different lighting systems

Metal doors insulation ECO

Since there is no insulation added to the door, use 1/8 MLV with 1/4 closed cell

foam ($14.63 per lineal ft.) bonded to it. Then cover with Super Soundproofing acoustical

mat. Usually 1 thick will suffice. Cut it a bit oversize to cover the seam of the door at the

frame to help seal it. You can use the mat with the adhesive backing if you want to re-use it

or remove it later.


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5.3: Evaluation of Energy and Procurement Strategies

Energizing Indianas Commercial and Industrial (C&I) Prescriptive Rebate Program

is specifically designed to help facility managers and building owners achieve long-term,

cost-effective energy savings. A prescriptive rebate structure provides your business ororganization with rebates based on the installation of energy efficiency equipment and system

improvements. Upgrades can include Lighting, Variable Frequency Drives (VFDs), HVAC,

and efficient ENERGY STAR commercial kitchen appliances.

Objectives of the C&I Prescriptive Rebate Program are to:

Help C&I facilities lower electric energy consumption Help C&I customers decrease their overall energy costs Encourage vendors and contractors to actively promote and install energy-efficient

technologies for their C&I customers

Weve built a network of HVAC, lighting and appliance suppliers and electrical contractors

to work with you to meet your energy-saving needs. Lower your energy costs today, and do

your part to energize Indiana!

Type Estimated kWh. Cost savings ($)

Lighting 3.2 1161

Door Insulation 0.5 182

Economizer 0.5 182

Thermostat 0.1 36

Total 4.3 1561

Table 5.3.1 shows the cost savings of different systems


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Section 6: Action Plan

6.1 Recommended ECOs and an implementation schedule

The main objective of this energy audit is to identify potential Energy Conservation

and Retrofit Measures and to determine whether or not the identified ECRMs are

economically feasible to warrant the cost for planning and implementation of each measure.

Economic feasibility of each identified measure was evaluated through a simple payback

analysis. The simple payback analysis consists of establishing the Engineers Opinion of

Probable Construction Cost estimates, O&M estimates, projected annual energy savings

estimates, and the potential value of Indiana Clean Energy rebates, or Renewable Energy

Credits, if applicable. The simple payback period is then determined as the amount of time(years) until the energy savings associated with each measure amounts to the capital

investment cost.

Ranking Type Initial cost diff. Operating cost savings Simple payback

1 Lighting 30,000 2900 10.3 yrs.

2 Door Insulation 500 275 1.8 yrs.

3 Economizer 2850 1150 2.5 yrs.

4 Thermostat 90 90 1.0 yrs.

Table 6.1 shows the simple payback years for different systems


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February 2nd Audit team visits the gymnasium

February 7th Energy bill analysis

February 14th

Meeting to discuss regarding potential ECOs

February 21st Finalize the potential ECOs

February 28th Submit the draft copy of the report

March 1st Submit the final copy of the report

March 6th Evaluation of the report

March 8th Finalizing of the ECOs

March 15th Release of funds for implementing ECOs

March 22nd Start of work to implement lighting ECO

March 26th Start of work to implement door insulation ECO

March 29th End of work to implement door insulation ECO

April 2nd Start of work to implement Economizer ECO

April 5th End of work to implement lighting ECO

April 9th Start of work to implement thermostat ECO

April 11th End of work to implement thermostat ECO

April 14th End of work to implement Economizer ECO

Table 5.2.1 shows the schedule for different ECOs and energy audit


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Department of Mechanical Engg Purdue University Calumet Page 21

Section 7: Conclusion and post implementation review

Lighting has the highest payback period, but the lifespan of the lighting systemsECO

suggested has the longest life span of over 100,000 hrs. and consume less energy to provide

the lighting at the same time since the life span is high it will have very low maintenance cost

and according to the working hrs. of the gymnasium.

As an immediate effect we can suggest to upgrade the lighting systems with the

Induction fluorescent, since it saves energy and has a longer life. These lighting systems can

be bought online or in store. It might need more hours of workmanship since more bulbs has

to be installed. It might take up to a week to complete the work.

As a second choice Door insulation can be done easily with in a day since there are

less no. of doors that are facing outside, transom seal may take a little more work since it

needs to be fixed with screws at the lower bottom end of the doors, but the foam tape do not

need much of the work.

Installing the economizer will increase the efficiency of the boiler and this might

require installing prefabricated heat exchangers and other fittings and it will consume less

time near the boiler.

Though programmable as recommended has a lesser cost cutting featurethermostat

directly but it saves lot of energy indirectly by better temperature management which is

directly proportional to cost cutting. It also eliminates the use of compressor which avoids

the initial and maintenance cost and also helps reduce the energy consumed by compressor.

From the below table we can estimate the savings from different type of ECOs

Type Estimated kWh. Cost savings ($)

Lighting 3.2 1161

Door Insulation 0.5 182

Economizer 0.5 182

Thermostat 0.1 36

Total 4.3 1561

Table 7.1 shows the cost savings from different systems

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