reducing cost of operating large and complex building … · reducing cost of operating large and...
TRANSCRIPT
Reducing Cost of Operating Large
and Complex Buildings via
Automation Improvements
Reprogramming automation
predictably yields savings and is
relatively inexpensive to
implement
Fran Boucher, Senior Engineer, National Grid
Bill Gnerre, CEO and Cofounder – Interval Data
Systems, Inc.
James Gardner, Director of Maintenance –
University of Massachusetts Medical Center
Greg Cmar, CTO and Cofounder – Interval Data
Systems, Inc.
John Baker, AVC Facilities – University of
Massachusetts Medical School
In Attendance Today
9.15.16 2
Safety Moment – Winter Wiper Blades
Low sun on the horizon
– vision clarity is
essential to safe driving
Snow and Ice are on
the way!
3
4
National Grid Service Territory
National Grid has a long standing role in new and existing labs.
Ventilation is #1
50 - 50 Split gas and electric energy savings
You may be a customer for one the other or both
We have learned along the way
Today is largely about intensifying efforts on controls (automation) and M&V
National Grid Role
9.15.16 5
Reducing Cost of Operating Large
and Complex Building via
Automation Improvements
Reprogramming automation
predictably yields savings and is
relatively inexpensive to implement
UMMS requirements to lower energy cost/improve building operations across the Campus
Case Study – Ambulatory Care Center (ACC)
Analysis Findings
Remediation Phase 1
Verification of Operational Impact
Remediation Phase 2
UMMS Lessons Learned
Best Practices to Achieve Results
National Grid Incentives
Agenda
9.15.16 7
UMMS – campus approximately 3M SF, building size 250K – 500K SF, building
utility cost $2.50 - $6.00/SF, primarily science buildings
LEED Certified Buildings (ACC & Sherman)
Maintain benefits of certification
Find additional savings
Needed a much better way to visualize how buildings truly operated than currently
available
Needed an more cost effective approach to improve building operations than
offered by engineering firms, control contractors, commissioning agents or ESCOs
Better information to make operational decisions than from than currently available Hold staff accountable
Organization wanted to improve accountability
Better information to determine investments
UMMC Desire to Improve
Operations through Data Analysis
9.15.16 8
The Problem – Why are Buildings
Inefficient from Day 1
Today’s design, construction and commissioning
process predictably delivers inefficient buildings.
And there’s a reason for that . . .
Design Engineering’s Role
Required • Must insure building will operate
at design conditions, hottest/coldest days, about 3% of the year (262 hours annually)
• ASHRAE requires set points on a per space basis to be determined, typically these points will have minimum/maximum temperature and airflow. This will insure the building always maintain safety.
• Identifies Sequence of Operations based upon ASHRAE standards
Not required
Does not specify how the building has to run over entire operating condition ranges. Not in business of operating building 24x365
Can’t know use of each space/zone so cannot determine approach to turn down each space.
SOO not specific and detailed enough to limit interpretation by control contractor
September 2016 10
General Contractor Role
Required
Deliver building, meet all
sign off requirements
Under pressure to get
occupancy certificate.
Owner under pressure
too.
Their business is to
construct the building
within budget and on-
time.
Not Required
Operate the buildings
24x365 for the next 20+
years
September 2016 11
Control Contractor Role
Required
Meet engineering spec
Control drawings meeting
SOO of engineering spec
Under pressure to get
done so that occupancy
certificate is issued
Business model is
hardware sales not high
quality automation
Not Required
Operate efficiently
Meeting ASHRAE
standards if not fully
communicated from
engineers spec
Nothing in their contract
obligates efficient
operations 24x365 for
20+years
September 2016 12
Commissioning Agent Role
Required
Commissioning guideline
(e.g. ACG) specifies
“functional testing” which
proves that equipment
functions
Equipment delivered and
in place
On-site services
Documentation
Not Required
Validate that building
operates efficiently
24x365
September 2016 BAS Recommissioning Service 13
Vendors are reluctant to take responsibility for insuring efficient 24X365 operations
This is the established contractual process in the industry which does not insure automation is vetted for 24X365X20+ year operations
Your options . .
Run inefficiently for the life of the equipment (20-30 years)
or
Remake the automation for the building as it is used
Conclusion
September 2016 14
Poll Questions
Commercial Electric and Gas
Customers
What kind of products / services
does your company offer?
1. Hospital / Healthcare
2. Multifamily Housing
3. Commercial Laundry
4. Manufacturing
1. Food
2. Pharmaceutical
3. Other
5. Other
Energy Professionals and
Contractors
What kind of products / services
does your company offer?
1. Engineering
2. Equipment Sales /
Distribution
3. Energy Consulting
4. HVACR
5. Other
15
AMBULATORY CARE CENTER
– CASE STUDY
Analysis and Recommendations Phase 1 – Analyst reviews
analytical software reports (FD & D), interprets, and presents
findings/recommendations
9.15.16 16
Ambulatory Care Center Overview
17
4 Variable volume AHUs serving
common plenum
Exhaust Fans (General)
Chilled water via central plant
Variable speed pumping based
on differential pressure
Hot water via 2 heat exchangers
Low pressure steam via central
plant
Moves 1.2 to 1.6 Billion Cubic Feet of
air per week
EUI 172 kBtu/SF
Engineering Design ~ 110 EUI
~ 5,000 points trended every 15
minutes
258,000 SF, Built 2009, 7 floors
Terminal Systems 525 VAVs (≈350
Supply, 175 Exhaust)
19 Fan Coils
119 Fan Powered VAVs
179 VAVs with reheat
198 Exhaust VAVs
209 Supply/Exhaust VAVs with reheat
Comprehensive Operational
Analysis
Uses 5,000 BAS trend points every 15 minutes and
metering data
BAS Analytic System installed for analysis, remediation
support, and on-going monitoring
Analyst Reviews: All systems and all equipment for
conformance with ASHRAE 36P standards using
weeks/months of historical operational data.
Remediation recommendations
Savings Quantification
18
BUILDINGS
ANALYSIS
REFERENCE:
ASHRAE 36-P
Unequivocal “playbook” to
run a building well
Excessive air flow during unoccupied time (60,000 CFM)
Excessive reheat during all hours
Comfort better in summer (score 9.5) than winter (score 8.4)
Identical AHUs operating differently
Unable to control number of AHUs operating based upon
terminal system demands
Building Analysis Revealed – System Level
9.15.16 20
Savings strategy – only deliver the required amount of air to each
space during all hours
Building Analysis Revealed – Equipment Level
Every piece
of equipment
reviewed
Pinpoint
broken
equipment
Identifies
common
themes
across
equipment
21
7th Floor Test Case to verify reduced air flow
22
Data verified we can
reduce air flow
Unoccupied air flow
reduced from ≈15,000 CFM
to ≈6,500 CFM
Confident change should
be implemented building
wide
BEFORE
AFTER
15,000 CFM
6500 CFM
Remediation Plan and Savings
9.15.16 National Grid Webinar 23
Measure Elec. Savings CHW Savings Steam Savings EUI Reduction
ECM-1 228,400 kWh 7,700 Ton-Day 2,662,600 lbs 21.9 kBTU/ft2
ECM-2 77,100 kWh 2,600 Ton-Day 899,300 lbs 7.4 kBTU/ft2
ECM-3 0 kWh 3,211 Ton-Day 3,585,713 lbs 17.5 kBTU/ft2
305,500 kWh 13,511 Ton-Day 7,147,613 lbs 46.8 kBTU/ft2
30,550.00$ 37,830.80$ 71,476.13$ 139,856.93$
Description
Reduce supply air flow throughout the
building at night.
Reduce daytime air flow by 20% by fully
utilizing occupancy sensors, in addition to
reduced air flow set points, as well as
calibration, repair and re-commissioning of
VAVs and RPCs.
Implement Supply air temperature reset at
AHUs
TOTAL
Current with ECM's Reduction
EUI 172 125.2 27.2%
Costs 814,600$ 674,743$ 17.2%
Incentive Submittal to National Grid
9.15.16 24
Total Incentive: $17,400
Poll Question
25
What is the biggest barrier to projects moving forward?
Lack of capital
Other higher priorities
Insufficient payback/ROI
Uncertainty regarding savings/performance
Other
If you selected, “Other”, what is the barrier?
ACC REMEDIATION PHASE 1
The path to remediation is never a straight line
9.15.16 26
Green indicates
part of the
planned
remediation
Red indicates
part of the
unplanned
remediation
Don’t worry
they’ll be plenty
of unexpected
items to fix
Remediation
Log
9.15.16 National Grid Webinar 27
IDS Remediation Plan Item Action Item(s) / Deficiencies (PLANNED / UNPLANNED) Deficency Type Date Started Date Completed ECM-1 ECM-2 ECM-3
Clean all flow stations Maintenance X X XRepair AHU-2 outdoor flow sensor Maintenance X X XInstall access panel @ AHU-1 Return flow station Maintenance X X XCalibrate flow station with balancer Maintenance X X X
Calibrate AHU static pressure sensors Calibrate all static pressure sensors (8) Maintenance 5/27/2015 6/24/2015 X X X
Configure applications for proper flow tracking Construction X X
Restore flow set points to design parameters Operations X X
Adjust volume dampers closed/mostly closed Operations X X
Adjust damper actuators Maintenance X XUndersized Ductwork Design X X
Reduce static pressure (1.85" to 1.65") Improvement 9/2/2015 9/2/2015 X X
Reduce static pressure (1.65" to 1.50") Improvement 9/30/2015 9/30/2015 X X
Further reduce static pressure (1.50" to ≈1.25") Improvement X XEvidence supports static pressure reset implementation
(based on terminal demand)Improvement
X X
Implement Test case: 7th floorProgram and test 7th floor 0 CFM during unoccupied validate
resultsImprovement 7/22/2015 10/30/2015
X X
Validate existing occupancy sensor operation (518) Maintenance 8/5/2015 10/30/2015 X X
Repair failed power supplies (12) Maintenance 10/30/2015 Ongoing X X
Wire sensors not previously wired during construction (229) Construction 10/30/2015 Ongoing X X
Enable sensor logic disabled during costruction per GC (38) Construction 7/22/2015 12/15/2015 X X
Add trends to occupancy sensors (≈250) Construction 10/30/2015 12/15/2015 X XModify program for terminals already programmed for min
flow when unoccupied (131) Improvement7/22/2015 Ongoing
X XCollect operating criteria for select zones (med rooms,etc) Improvement 10/30/2015 11/14/2015 X X
Validate 7th floor reduction resultsImprovement 10/30/2015 10/30/2015 X X X
Utilize 7th floor results to refine savings estimates Improvement 10/30/2015 11/11/2015 X X XConfirm buiding can on one AHU at night Improvement 1/23/2016 1/23/2016 X X XEvidence supports sequence change to operate one AHU at
night Improvement X X X
Validate air flow reductions at floor level Improvement 10/30/2015 Ongoing X X XValidate air flow reduction at building level (weekly air
volume) Improvement 10/30/2015 Ongoing X X X
Identify & repair chilled water meter Maintenance 2/3/2016 2/17/2016 X X XIdentify & repair failed electric meter (PH.EM.MAIN.PSB4) Maintenance 2/17/2016 Ongoing X X X
Increase AHU supply temperature from 55 to 58 Improvement 2/3/2016 2/17/2016 XEvidence supports supply temperature reset implementation
(based on terminal demand) ImprovementX
ACC Remediation Activity Log
5/27/2015 7/22/2015
6/10/2015 8/5/2015
Supply Air ResetFuture Action
Future Action
Future Action
Calibrate Air Flow Stations
Reprogram VAV Boxes (across all floors)
Resolve Dampers Issues
Validate Meter Data
Verify Air Flow Reduction Results
Future Action
Implement Static Pressure reset
Unplanned Remediation –
Occupancy Sensor Revelation
9.15.16 28
FLOOR Programmed
7 11
Programmed
6 18
5 17
4 21
3 17
2 29
1 9
A 9
TOTAL 131 TOTAL
Boxes Needing Wiring
32
31
Total Boxes
68
Boxes Needing Wiring
19
73
72
75
76
47 (23 Occ all the time)
33
24
41
39
10
Total Boxes
26.5% of the boxes are programmed
33
c.10 - Pharmacy & Med Rooms
6
12 + 4 Mammog Rms + 3 Med Rms
0
0
9 +2 Critical Rooms
2
74
0
Programmed but Disabled
Programmed but Disabled
495 (not including
the first floor occ ones)
Never anticipated the magnitude of this issue, sensors
controlled lights but was not carried through to HVAC System
Analysis showed that
135 of 525 VAV boxes
were not responding to
command to reduce
air flow. Why?
Discovered controllers
had the code required
to operate with lower
air flow but 6 years
prior it was
“commented out”
disabling the function
by the GC
Planned Remediation - Disabled
Capability Revelation
While we had planned to enable air flow reduction at the
VAV’s we thought we had to add automation code instead
we found it already existed, it was just disabled 29
Cost to implement construction based deficiencies and
energy savings:
Internal: 550 hours to date ($45K), additional required
IDS: $56,000 (S/W, Initial Analysis/Plan, Remediation
Service)
Total to date: $101K
Unaccounted Cost (over the past 6 years)
Energy waste
Maintenance efforts
Simple Payback – Less than .75 years
Cost Perspective
9.15.16 National Grid Webinar 30
RESULTS TO DATE FROM
REMEDIATION PHASE 1
9.15.16 31
As remediation
activities were
implemented total
air flow through
the building was
reduced
Approximately
400M CF of air
flow was
eliminated
Building Air Flow Reduction
9.15.16
32
Remediation
Process Begins
EUI
Reduction
9.15.16
Reached 60% of goal for energy and air flow reduction
Static pressure ECM was not implemented
Remediation Phase 1 Overall Results
9.15.16 35
Poll Question
36
Have you worked with National Grid in the past on an energy
saving project?
Yes / No
Would you like to speak with a National Grid expert on a
current steam heating system opportunity that you are or
would like to pursue?
Yes / No
ACC REMEDIATION PHASE 2
9.15.16 37
Further Analysis Revealed
Data identified 102
boxes were not turned
down fully
34,000 CFM (47%) of
unoccupied flow
results from box
minimums not set to 0
in unoccupied hours.
Problem . .reheat is
required in full cooling
season
9.15.16 38
Optimizing AHU Operations
Data indicated
that 3 AHU
systems were
running in the
middle of the night
.. Even though UM
thought they were
operating one
Found flaw in
automation
39
Air Handlers Automation 04190 C UNOCC STAGES BASED ON STATIC
PRESSURE -SJD 5/12/16-
04200 $LOC5 = "%Y%SSP"
04201 IF($LOC6 .EQ. OFF) THEN
SET(1,"%Y%REQ") ELSE GOTO 4210
04202 ON ($LOC6)
04210 IF("%Y%REQ" .LT. 1) THEN
SET(1,"%Y%REQ")
04220 IF("%Y%REQ" .GT. 4) THEN
SET(4,"%Y%REQ")
04230 IF("%Y%REQ" .EQ. 1) THEN GOTO 4310
04240 IF("%Y%REQ" .EQ. 2) THEN GOTO 4350
04250 IF("%Y%REQ" .EQ. 3) THEN GOTO 4390
04260 IF("%Y%REQ" .EQ. 4) THEN GOTO 4440
…
04785 C IF("ACC.AHU03.OAT" .GT.
"ACC.AHU.OA.UNOCC.OVRD") THEN
SET(2,"%Y%REQ")
ELSE SET(2,"%Y%REQ")
04786 C CHANGED LINE 4785 FROM ELSE(1) TO
ELSE(2) PER BOB CONDRON DUE TO
PHARMACY NEEDIN
04787 C IN OFF HOURS -SJD- 3/20/13
04790 C LINE 4785 NO LONGER NEEDED DUE TO
4200 SECTION -SJD 5/12/16-
We found that the automation logic for
scheduling the number of air handlers was
linked to CFM settings and not linked to
static pressure and CFM settings
40
LESSONS LEARNED
9.15.16 41
Commissioning process is designed to insure basic functions, which is very different
than operating efficiently day in day out for the next 25-30 years
Use of analysis software, routine review of data, and automation corrective actions
consistently yields attractive results
Misalignment of Sequence Of Operations and design intent results in energy waste
and staff futility and comfort issues
ASHRAE 36P (High Performance Building Standard)
Nicely consolidates the BAS automation requirements
It’s the “playbook” to operate your building (not just for design)
We now have an inexpensive process that predictably lowers on-going building
operations (energy and maintenance) cost primarily through automation changes
Continuously monitor data helps prioritize maintenance work, very different approach
with better results than traditional retro-commissioning
Lesson Learned
9.15.16 42
BEST PRACTICES – GETTING
THE AUTOMATION RIGHT
One can predictably achieve significant operational improvements
by aligning the automation to ASHRAE/ANSI Standards at a
relatively low cost. Automation affects building operations for the
life of the building (20-30 years)
9.15.16 43
Needed - Automation that enables
driverless building
Automating driving a car is much more complex than automating
the operation of a building yet after all these years, not even close.
9.15.16 44
Must have on-going BAS data required to analyze,
support remediation and for on-going monitoring
A building’s automation (programming) must strictly
conform to ASHRAE/ANSI best practices (36P, 60.1,
90.1, etc.) by system and device
It is likely that it will take a couple of iterations to make
sure the automation performs as desired
Keep looking at the data
Automation Best Practices
9.15.16 45
Buildings Characteristics
Science, research, labs, hospitals, multi-use
Large with many components and systems
Less than 7 years since last major BAS overhaul
Utility Perspective
High EUI
High $/SF utility costs
Total Utility Costs >$500K annually
Interval Data Meters
Buildings requiring significant on-going maintenance efforts
BAS
Johnson Controls, Siemens, Tridium, Automated Logic, Andover Controls
Candidates for improved automation
9.15.16 46
Here to educate you and assist you with taking action
Free preliminary facility review
Help finding outside engineering firms
Assistance with cost of detailed analysis where applicable
Project Incentives for Energy Savings
National Grid’s Role
9.15.16 47
May be a capital or O&M project
Different incentive programs for each
Automation changes that directly affect reducing costs
Analysis not eligible for incentives
Monitoring is not eligible for incentives
For some we need to coordinate with another utility for gas or
electric incentives
Potential for additional incentives for recent projects
National Grid’s Incentives
9.15.16 48
Poll Question
49
How valuable has this webinar been to you?
1. Not valuable at all. The content was too technical and detailed
for me to understand.
2. Slightly valuable. It was worth attending, but I would not
recommend it to anyone.
3. Moderately valuable. Content was interesting and informative,
but only increased my knowledge or comfort level a little.
4. Very valuable. This was time well spent and I learned a lot.
5. Extremely valuable. My knowledge of National Grid offerings
and opportunity has increased considerably.
50
Thank you - Q&A
Fran Boucher, National Grid
Bill Gnerre, Interval Data Systems, Inc.
James Gardner, University of
Massachusetts Medical Center
Greg Cmar, Interval Data Systems, Inc.
John Baker, University of Massachusetts
Medical School
APPENDIX
9.15.16 51
Albert Sherman Center
HVAC Systems
2 common header, dedicated OA VAV systems (4 AHU units each) with enthalpy wheel heat recovery Serving Main Building
406 VAV/CAV terminal units
340 VEV exhaust units
411 chilled beam
73 Phoenix hoods
66 Phoenix VAV terminal units
10 Phoenix VEV exhaust units
2 dedicated OA VAV systems with Konvekta heat recovery serving Vivarium
5 VAV/CAV terminal units
4 VEV exhaust units
81 Phoenix VAV terminal units
43 Phoenix VEV exhaust units
1 displacement ventilation system with twin supply units and common return
69 VAV/CAV terminal units
1 supply/return system with economizer
57 VAV/CAV terminal units
9.15.16 National Grid Webinar 52
Built 2013
512,000 GSF Labs
Offices
Classrooms
Restaurant
EUI Design – 204 kBtu/SF
Actual – 308 kBtu/SF
Currently operating at 308 EUI
Design is for 204 EUI
Controlling Airflow will yield 70 EUI reduction or approximately $400K annually
BAS programming root cause of inefficiency
Secondary AHU systems
Terminal systems
Air quality system improperly implemented
Fixable problem with < 12 month simple payback
Summary of Operational Findings
9.15.16 National Grid Webinar 53
Excessive air flow
Overall building operating at 7.6 ACH
Minimal airflow reduction during unoccupied hours
No airflow reduction during occupied hours when rooms are unoccupied
Vacancy/Occupancy Sensor were evaluated
Reviewed 165 of 948 terminal boxes
No activity – 128
Always on – 9
Sensor works but no control – 28
Number operating as required – 0
Several automation deficiency examples
Managing Air Flow
Managing Temperature set points
Vacancy/Occupancy sensors are not configured correctly
Summary of Operational Findings
9.15.16 National Grid Webinar 54
Automation Review - AHU
Performance Versus ASHRAE
Requirements
9.15.16 55
Picture tells a 1000 Words
Controls system are not designed for comprehensive operational
analysis rather just an instant of time.
Typical BAS Display
Captures data for
an instant in time
for a specific
piece of
equipment
Not designed to
compress
massive amounts
of data to readily
interpret meaning
Not designed to
readily navigate
across time
~ 25 data points57
EnergyWitness Display
Full week of data
at a glance
4 different
systems level
pictures
Readily look
across
weeks/months of
data in minutes
~ 10,000 data
points
58