Reducing Cost of Operating Large and Complex Building … · Reducing Cost of Operating Large and Complex Building via ... UMMS –campus approximately 3M SF, ... Organization wanted

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


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


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




…

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

[email protected]

Bill Gnerre, Interval Data Systems, Inc.

[email protected]

James Gardner, University of

Massachusetts Medical Center

Greg Cmar, Interval Data Systems, Inc.

[email protected]

John Baker, University of Massachusetts

Medical School

mailto:[email protected]



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


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


1 supply/return system with economizer



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


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


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

Documents

Reducing Cost of Operating Large and Complex Building … · Reducing Cost of Operating Large and Complex Building via ... UMMS –campus approximately 3M SF, ... Organization wanted