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Session	
  E4:	
  Energy	
  Audi1ng	
  

Energy	
  Audits	
  In	
  Ac1on	
  
Lonnie	
  Russell,	
  CEM	
  
 	
  Energy	
  Audits	
  in	
  Ac/on	
  	
  by	
  	
  EnergyMan	
  LLC	
  
Plan	
  of	
  A8ack	
  
Building	
  Energy	
  Usage:	
  Non	
  Industrial
Environmental	
  Control

Ligh1ng

20%

The goal is to try to
make the biggest
impact possible
with little or no
investment. Start
with the largest
electrical loads and
gas users.

Includes
HVAC and
hot water

30%

50%

Other
Important Question: Why is this operating with no one here?
Must do some of audit during non-occupied times
These items were found on 24/7 during non-occupied times.
Programmable thermostat in override and set to
68F in the summer

Boiler

10 Air handlers with a combined horsepower of 68.5
This	
  is	
  equipment	
  in	
  the	
  
cabana;	
  only	
  used	
  
seasonally,	
  but	
  it	
  was	
  all	
  
on;	
  3	
  refrigerators	
  were	
  
empty	
  and	
  on,	
  stove	
  
had	
  it’s	
  pilot	
  light	
  on	
  
and	
  hot	
  water	
  heater	
  
was	
  	
  not	
  turned	
  off.	
  
The	
  auditorium	
  is	
  a	
  very	
  large	
  space	
  to	
  leave	
  the	
  
HVAC	
  system	
  running	
  when	
  the	
  room	
  is	
  not	
  in	
  use	
  
Computer	
  monitors	
  leS	
  on	
  
The	
  current	
  IT	
  PC	
  policy	
  is	
  not	
  helping	
  with	
  PC	
  
power	
  consump/on,	
  as	
  can	
  be	
  observed	
  by	
  the	
  
hundreds	
  of	
  PC’s	
  that	
  are	
  leS	
  on	
  24/7.	
  

At	
  an	
  absolute	
  minimum,	
  the	
  monitors	
  should	
  be	
  set	
  to	
  to	
  go	
  to	
  
standby.	
  Leaving	
  these	
  all	
  on	
  puts	
  a	
  heavy	
  load	
  on	
  the	
  HVAC	
  
system,	
  which	
  may	
  not	
  have	
  been	
  originally	
  designed	
  for	
  this	
  large	
  
a	
  load.	
  
Cost per Year
Motor Size
8 cents / kWh 11 cents / kWh
1 kW
$611
$964
10 kW
$7,008
$9,636
25 kW
$17,520
$24,090
50 kW
$35,040
$48,180
1 Hp
$680
$934
10 Hp
$6,796
$9,344
25 Hp
$16,989
$23,360
50 Hp
$33,978
$46,720
Ini/al	
  motor	
  cost	
  is	
  only	
  about	
  5%	
  of	
  the	
  total	
  
lifecycle	
  cost,	
  so	
  always	
  buy	
  an	
  efficient	
  motor!	
  
Why	
  does	
  equipment	
  not	
  get	
  turned	
  off?:	
  

• 	
  	
  Lack	
  of	
  control	
  of	
  building	
  during	
  off	
  hours,	
  especially	
  in	
  buildings	
  with	
  mul/ple	
  users	
  

• 	
  	
  	
  System	
  was	
  set	
  up	
  that	
  way	
  from	
  the	
  beginning	
  and	
  no	
  one	
  on	
  site	
  knows	
  how	
  to	
  correct	
  it.	
  
• 	
  	
  	
  It	
  has	
  always	
  been	
  that	
  way	
  so	
  no	
  one	
  no/ces.	
  
• 	
  	
  	
  We	
  tried	
  that	
  once	
  but….	
  
• 	
  	
  	
  You	
  can’t	
  turn	
  that	
  off.	
  It	
  may	
  not	
  turn	
  back	
  on	
  (my	
  personal	
  favorite).	
  

This is not
limited to smaller
facilities. Here
are some sizable
loads at a large
facility.

Chiller and associated
equipment

Chiller	
  Primary	
  and	
  Secondary	
   Cooling	
  Tower	
  Pumps
	
  
pumps
	
  

Cooling	
  Towers
	
  
Now	
  that	
  the	
  schedule	
  is	
  op/mized	
  how	
  do	
  we	
  make	
  our	
  
HVAC	
  system	
  more	
  efficient?	
  
• 	
  	
  Tighten	
  up	
  the	
  building	
  and	
  ductwork	
  

•  Control	
  the	
  outside	
  air	
  (preferably	
  with	
  demand	
  controlled	
  	
  	
  
ven1la1on)	
  and	
  Economize,	
  if	
  possible	
  
• 	
  	
  	
  	
  Install	
  VFD’s	
  where	
  possible	
  
• 	
  	
  	
  	
  Ligh1ng	
  	
  
• 	
  	
  	
  	
  Energy	
  efficiency	
  products	
  
• 	
  	
  	
  	
  Minimize,	
  or	
  eliminate	
  reheat	
  
•  	
  Op1mize	
  the	
  set	
  points	
  (room	
  temp,	
  chill	
  water,	
  hot	
  water,	
  non-­‐
occupied,	
  occupied	
  etc…)	
  
• 	
  	
  	
  ASHRAE	
  states	
  that	
  80%	
  of	
  all	
  occupants	
  will	
  be	
  comfortable	
  
at	
  temperatures	
  of	
  68F	
  to	
  74F	
  in	
  the	
  winter	
  and	
  73F-­‐78F	
  in	
  the	
  
summer	
  at	
  no	
  >	
  60%	
  RH.	
  
SCGSAH	
  1st	
  year	
  Results	
  (opera/onal	
  changes	
  only!)	
  
Natural Gas Usage

Electricity Usage

16,000

350,000

2008

300,000

2009

Therms

KWH

11,000

250,000
200,000
2008

150,000

6,000

Reduc/on	
  of	
  51.7%	
  

2009

100,000
Dec Jan Feb Mar Apr May Jun

Time

1,000
Dec

Jan

Feb

Mar

Apr

May

Jun

Reduc/on	
  Time8.6%	
  
of	
  2

Jul

YTD Natural Gas Cost

YTD Electricity Cost
150000

100000
YTD
50000

Dollars

150000

Dollars

Jul

100000
YTD

50000
0

0
2008

2009

Time
Reduc/on	
  of	
  60.4%	
  

2008

2009

Time
Reduc/on	
  of	
  18.4%	
  
Building	
  Envelope	
  Improvement	
  
This	
  building	
  had	
  many	
  major	
  air	
  leaks	
  that	
  needed	
  to	
  be	
  addressed.	
  Major	
  leaks	
  included:	
  
• Exhaust	
  fans	
  with	
  no	
  dampers	
  so	
  they	
  would	
  be	
  wide	
  open	
  when	
  not	
  running	
  
• Overhead	
  doors	
  with	
  no	
  seals	
  
• Bathroom	
  exhaust	
  fans	
  that	
  never	
  shut	
  off	
  
• Large	
  gaps	
  around	
  fan	
  shrouds	
  
• Large	
  louvers	
  that	
  were	
  open	
  to	
  the	
  outside	
  
Open	
  Exhaust	
  Duct	
  

BackdraS	
  Damper	
  Installa/ons
	
  
Air infiltration repair (Overhead doors)

Before
	
  

Before	
  (sunlight	
  leaking	
  in)
	
  

ASer
	
  

Curtain	
  for	
  
frequently	
  used	
  door
	
  

Brush	
  seal
	
  
Brush	
  Seal
	
  
Building Envelope and Leaky ductwork examples

Faulty	
  	
  Duct	
  Insulation
Open Roof Access

No floor insulation in crawl space

Missing	
  	
  Insulation

OA damper stuck open
Ductwork insulation in bad shape
Negative Pressure from Bathroom Exhaust Fans
Bathroom	
  Exhaust	
  fans	
  were	
  on	
  24/7.	
  When	
  HVAC	
  equipment	
  was	
  shut	
  down,	
  these	
  fans	
  
exhausted	
  2000	
  cfm	
  and	
  pulled	
  air	
  in	
  from	
  outside	
  causing	
  humidity	
  to	
  rise	
  at	
  night.
	
  

Fan	
  switches	
  were	
  hidden	
  
and	
  always	
  leS	
  on
	
  

Sensors	
  were	
  installed	
  to	
  automate	
  the	
  bathroom	
  exhaust	
  fans	
  so	
  
they	
  would	
  run	
  for	
  15	
  minutes	
  when	
  the	
  bathroom	
  became	
  
unoccupied	
  and	
  then	
  shut	
  off.
	
  
Outside	
  air	
  control	
  opportuni/es	
  
Some	
  places,	
  such	
  as	
  churches	
  and	
  auditoriums,	
  have	
  high	
  outside	
  air	
  requirements	
  
because	
  of	
  the	
  per	
  person	
  ASRAE	
  ven/la/on	
  requirements.	
  This	
  is	
  partly	
  to	
  prevent	
  the	
  
“sick	
  building	
  syndrome”	
  issues	
  that	
  occurred	
  when	
  buildings	
  did	
  not	
  ven/late	
  
adequately	
  in	
  the	
  past.	
  

Sanctuary	
  Outside	
  Air	
  Intake

Using	
  CO2	
  monitoring,	
  and	
  controlling	
  the	
  outside	
  air	
  intake	
  based	
  on	
  that,	
  allows	
  for	
  proper	
  
outside	
  air	
  intake.	
  Otherwise,	
  you	
  could	
  be	
  bringing	
  in	
  the	
  outside	
  air	
  requirement	
  for	
  
hundreds	
  of	
  people	
  no	
  ma8er	
  how	
  small	
  the	
  occupancy	
  is.	
  This	
  technique	
  is	
  called	
  “demand	
  
controlled	
  ven/la/on”.	
  The	
  price	
  to	
  do	
  this	
  type	
  of	
  control	
  has	
  dropped	
  substan/ally	
  in	
  the	
  
last	
  few	
  years,	
  with	
  CO2	
  sensors	
  now	
  barely	
  over	
  $100.00	
  and	
  damper	
  controllers	
  for	
  about	
  
the	
  same.	
  
Demand	
  Controlled	
  Ven/la/on	
  

Outside Air
Dampers
AHUs were initially set at 10% - 15% OA damper open at all times. Especially in
the hot humid summers of South Carolina, this can unnecessarily load the
system. CO2 sensors were installed and set to open the OA dampers if CO2 levels
rise to levels > 1000 ppm.
Make	
  outside	
  air	
  your	
  friend!	
  	
  Economize	
  (frequently	
  called	
  free	
  cooling)	
  for	
  your	
  
winter	
  heat	
  loads.	
  Able	
  to	
  shut	
  down	
  all	
  but	
  the	
  air	
  moving	
  parts	
  of	
  the	
  HVAC	
  
systems	
  (chillers,	
  pumps,	
  compressors	
  etc…).	
  

Economizer	
  possible	
  for	
  2309	
  to	
  3961	
  hours.	
  High	
  bays	
  maybe	
  
an	
  addi/onal	
  1000	
  hours.	
  
Equipment	
  Modifica/ons/Requirements	
  to	
  Economize	
  

Outside	
  air	
  damper	
  can	
  
only	
  be	
  open	
  or	
  closed:	
  
cannot	
  be	
  modulated.	
  

Installed	
  
Modulator
	
  

Return	
  air	
  had	
  no	
  
damper,	
  therefore	
  
ra/o	
  of	
  return	
  versus	
  
outside	
  air	
  cannot	
  be	
  
controlled.
	
  

Installed	
  
Modula/ng	
  
Damper
	
  
Advantages	
  of	
  a	
  Variable	
  Frequency	
  Drives	
  (VFD’s)	
  
HVAC	
  systems	
  are	
  generally	
  built	
  for	
  the	
  10	
  hoYest	
  and	
  10	
  coolest	
  days	
  of	
  the	
  year.	
  There	
  is	
  
generally	
  overcapacity	
  for	
  all	
  other	
  condi[ons.	
  VFD’s	
  offer	
  the	
  ability	
  to	
  match	
  the	
  system	
  to	
  
the	
  load,	
  offering	
  tremendous	
  energy	
  savings	
  and	
  extending	
  equipment	
  life.	
  	
  

A 50% reduction in flow actually reduces
horsepower requirements by 87.5%
Pumping	
  power	
  is	
  wasted	
  (valves	
  are	
  par/ally	
  closed)	
  making	
  the	
  pumps	
  good	
  VFD	
  (variable	
  
frequency	
  drive)	
  candidates.	
  The	
  pumps	
  (2)	
  also	
  run	
  con/nuously.	
  
Variable	
  Frequency	
  Drive	
  HVAC	
  Applica/ons	
  

40	
  Hp	
  high	
  bay	
  air	
  handler.	
  

Cooling	
  Tower	
  Pump	
  VFD:	
  Since	
  the	
  small	
  
chiller	
  only	
  needs	
  900	
  gpm	
  and	
  the	
  
exis/ng	
  pump	
  supplies	
  2000	
  gpm,	
  a	
  VFD	
  
was	
  far	
  more	
  efficient	
  than	
  a	
  thro8le	
  
valve	
  (see	
  previous	
  slide).
	
  

30	
  Hp	
  high	
  bay	
  air	
  handler.	
  	
  

AHU’s:	
  Original	
  owner	
  of	
  Bldg.	
  needed	
  100%	
  OA	
  for	
  the	
  manufacturing	
  space.	
  New	
  owner	
  did	
  not	
  need	
  
that	
  so	
  VFDs	
  were	
  used	
  to	
  thro8le	
  these	
  drives	
  down	
  significantly.	
  This	
  also	
  allowed	
  for	
  dehumidifica/on	
  
control	
  (by	
  moving	
  the	
  air	
  very	
  slow	
  and	
  lowering	
  the	
  chill	
  water	
  temperature)	
  and	
  reduced	
  load	
  on	
  the	
  
chiller	
  and	
  boiler.	
  
Reheat	
  Reduc/on	
  using	
  variable	
  airflow	
  	
  
Fast Airflow

Slow Airflow

OA
damper

OA
65F damper

Cooling
Coil
RA
damper

Filter Air

Temp

Reheat
Coil

50F
Cooling
Coil

Fan

Air
Temp

Original Line-up (simplified with no exhaust):
Air moved at max CFM across the cooling coil
that had 42F chilled water going through it. This
dropped the temperature. This colder air was
then passed across a reheat coil that had 180F
water going through it. This brought the air to a
normal discharge temperature of 55F – 65F.

RA
damper

Filter Air

Temp

Reheat
Coil

Fan

Air
Temp

New De-humidification line-up (simplified with no exhaust):
Air moved at min CFM across the cooling coil that had 42F 47F chilled water going through it. This drops the
temperature significantly, condensing more water therefore
reducing humidity. The need for reheat is reduced or
eliminated. The reduced airflow helps keep the space from
getting too cold, but a little reheat may be required if that
occurs. As you can see the low discharge air temperature
means the supply air duct definitely has to be insulated.
Elimina/ng	
  reheat	
  required	
  the	
  high	
  bay	
  
ductwork	
  to	
  be	
  insulated	
  because	
  the	
  
discharge	
  air	
  temp	
  would	
  drop	
  and	
  
swea/ng	
  could	
  occur.	
  This	
  was	
  an	
  
$18,000	
  investment	
  with	
  a	
  payback	
  of	
  
about	
  1	
  month!	
  
Natural	
  Gas	
  Consump/on	
  Results
	
  
Natural Gas Consumption
2500
2006
2007

Dekatherms

2000

2008

1500

228	
  
CDD	
  

1000

500
320CDD	
  
231	
  CDD	
  

0
1

2

3

4

5

6

7

8

9

10

11

12

Though	
  Nov08	
  was	
  
very	
  cold,	
  with	
  a	
  
28%	
  increase	
  in	
  
CDD,	
  gas	
  usage	
  only
increased	
  12.8%	
  

Month

Natural	
  gas	
  consump/on	
  has	
  been	
  the	
  largest	
  success	
  of	
  our	
  energy	
  management	
  efforts.	
  Overall	
  Results:	
  
• 	
  Dekatherms	
  reduced	
  by	
  87.8%	
  
• 	
  Cost	
  reduced	
  	
  $239,728	
  for	
  a	
  cost	
  reduc/on	
  of	
  	
  89.2%	
  
Domes/c	
  Hot	
  Water	
  

• 
• 
• 
• 
• 

Electronic	
  Timers	
  should	
  be	
  installed	
  on	
  electric	
  water	
  heaters.	
  
Many	
  facili/es	
  have	
  water	
  heaters	
  that	
  are	
  grossly	
  oversized	
  
NG	
  should	
  be	
  used	
  if	
  available	
  (Far	
  less	
  expensive	
  to	
  heat	
  with	
  than	
  electric	
  resistance)	
  	
  
Tankless	
  NG	
  systems	
  are	
  ideal	
  for	
  low	
  or	
  variable	
  occupancy	
  applica/ons	
  	
  
Heat	
  Pump	
  water	
  heaters	
  are	
  good	
  for	
  hot	
  kitchens	
  
HW	
  recircula/on	
  pumps	
  

When	
  water	
  heaters	
  are	
  turned	
  off,	
  their	
  associated	
  recircula/on	
  pumps	
  need	
  to	
  
be	
  turned	
  off	
  also.	
  If	
  not,	
  they	
  will	
  cause	
  the	
  piping	
  system	
  to	
  act	
  as	
  a	
  large	
  
radiator,	
  removing	
  heat	
  from	
  the	
  hot	
  water	
  tank,	
  causing	
  the	
  water	
  heater	
  to	
  use	
  
more	
  energy	
  on	
  start-­‐up	
  (to	
  reach	
  set	
  point).	
  This	
  energy	
  loss	
  is	
  in	
  addi/on	
  to	
  the	
  
energy	
  use	
  to	
  operate	
  the	
  pump	
  
Vending	
  Misers	
  

•  Install	
  Vending	
  Miser	
  on	
  soda	
  machines:	
  	
  
h8p://www.usatech.com/energy_management/energy_vm.php	
  
•  Shuts	
  down	
  the	
  compressor	
  and	
  lights	
  when	
  people	
  are	
  not	
  in	
  the	
  
area	
  
•  Can	
  have	
  a	
  payback	
  of	
  less	
  than	
  one	
  year	
  
•  Simple	
  to	
  install	
  requiring	
  li8le	
  technical	
  skills	
  
•  Some/mes	
  soda	
  vendor	
  will	
  supply	
  for	
  free	
  
•  Soda	
  s/ll	
  stays	
  cold	
  
Many	
  opportuni/es	
  for	
  vending	
  and	
  cooler	
  misers	
  	
  
Many	
  drink	
  coolers	
  
have	
  very	
  bad	
  seal	
  
leaks	
  

“`	
  

A	
  vendor	
  supplies	
  these	
  coolers	
  to	
  this	
  golf	
  resort,	
  but	
  the	
  resort	
  s/ll	
  has	
  to	
  pay	
  the	
  
u/lity	
  bill!	
  	
  These	
  are	
  basically	
  opera/ng	
  with	
  the	
  door	
  leS	
  open.	
  
Refrigerated	
  Water	
  Fountains	
  

Use	
  of	
  a	
  
programmable	
  
receptacle	
  can	
  
reduce	
  water	
  
fountain	
  	
  power	
  
use	
  by	
  30%	
  
The	
  hood	
  should	
  overhang	
  6”	
  over	
  the	
  cooking	
  	
  equipment.	
  Either	
  
the	
  equipment	
  needs	
  pushed	
  back	
  a	
  li8le	
  more	
  or	
  extensions	
  need	
  
installed	
  on	
  the	
  hood.	
  
Dishwasher	
  sani/zing	
  heaters,	
  such	
  as	
  these	
  two	
  36	
  kW	
  models,	
  can	
  
consume	
  up	
  to	
  30%	
  of	
  a	
  restaurants	
  total	
  power	
  use.	
  Should	
  consider	
  
a	
  NG	
  unit	
  or	
  a	
  chemical	
  dishwasher	
  
Dishwasher	
  exhaust	
  is	
  on	
  	
  when	
  
dishwasher	
  is	
  not	
  opera/ng.	
  Best	
  fix	
  is	
  
an	
  interlock	
  
Pilot	
  lights	
  should	
  be	
  	
  
shut	
  off	
  whenever	
  
possible	
  

Idle	
  /me	
  needs	
  to	
  be	
  reduced	
  
whenever	
  possible	
  
Pilot	
  lights	
  are	
  leS	
  on	
  con/nuously	
  

Assume	
  1,250	
  BTUs	
  for	
  commercial	
  pilot.	
  This	
  is	
  a	
  two-­‐fold	
  savings:	
  natural	
  gas	
  or	
  
propane	
  to	
  fuel	
  the	
  pilot	
  and	
  the	
  electricity	
  saved	
  by	
  not	
  having	
  to	
  remove	
  the	
  heat	
  with	
  
the	
  HVAC	
  system.	
  A	
  4	
  burner	
  stove	
  (they	
  are	
  usually	
  larger)	
  would	
  require	
  10	
  tons	
  of	
  
cooling	
  to	
  remove	
  the	
  heat	
  from	
  the	
  pilots!	
  
Walk-­‐Ins	
  	
  
No	
  curtains	
  	
  

Example	
  of	
  
a	
  plas/c	
  
curtain	
  that	
  
would	
  work	
  
well	
  in	
  the	
  
walk-­‐in	
  
coolers	
  and	
  
freezers	
  
Ligh/ng	
  Opportuni/es	
  
Incandescent	
  Auditorium	
  Lights	
  

Too	
  much	
  aisle	
  light	
  

Most	
  painless	
  energy	
  
project!	
  Replace	
  
incandescent	
  exit	
  signs	
  
with	
  LED	
  signs.	
  About	
  a	
  6	
  
month	
  payback	
  and	
  no	
  
complaints!	
  
500	
  T12	
  lights	
  on	
  at	
  0100	
  in	
  the	
  morning	
  in	
  a	
  large	
  library	
  
Many	
  /mes	
  hallways	
  are	
  over-­‐illuminated.	
  Rarely	
  should	
  a	
  4	
  bulb	
  
fixture	
  be	
  used	
  in	
  a	
  hallway.	
  The	
  Illumina/ng	
  Engineering	
  Society	
  of	
  
North	
  America	
  (IESNA)	
  maintains	
  that	
  10-­‐20	
  fc	
  is	
  adequate	
  for	
  
hallways	
  and	
  aisles.	
  These	
  were	
  50	
  fc	
  or	
  higher.	
  
Reduced	
  Ligh/ng	
  Plan	
  on	
  the	
  cheap
	
  
This	
  is	
  an	
  inexpensive	
  way	
  to	
  secure	
  ligh/ng	
  that	
  does	
  not	
  have	
  switches.	
  This	
  example	
  is	
  for	
  high	
  bay	
  
ligh/ng	
  (uses	
  much	
  more	
  energy	
  than	
  office	
  ligh/ng).	
  The	
  breakers	
  we	
  labeled	
  and	
  security	
  was	
  trained	
  
to	
  turn	
  them	
  off	
  when	
  they	
  are	
  not	
  needed.	
  This	
  reduced	
  the	
  off-­‐shiS	
  load	
  by	
  35	
  –	
  50	
  KW	
  with	
  no	
  capital	
  
required,	
  just	
  labeling	
  and	
  a	
  procedure.	
  The	
  lifespan	
  of	
  the	
  breakers	
  was	
  inves/gated	
  and	
  it	
  was	
  found	
  
that	
  they	
  should	
  last	
  over	
  11	
  years	
  if	
  they	
  are	
  cycled	
  twice	
  a	
  day.	
  
Ligh/ng	
  Upgrades	
  

This	
  hi	
  bay	
  was	
  converted	
  from	
  250w	
  HPS	
  to	
  T8	
  fluorescent.	
  32	
  fixtures	
  were	
  replaced	
  with	
  16	
  4’s	
  and	
  16	
  
6’s.	
  This	
  reduced	
  wa8age	
  by	
  3,242	
  wa8s	
  and	
  HVAC	
  by	
  1902	
  tons.	
  This	
  project	
  was	
  done	
  in	
  conjunc/on	
  
with	
  installing	
  switches	
  that	
  allowed	
  for	
  all	
  but	
  6	
  lights	
  to	
  be	
  off	
  when	
  the	
  space	
  was	
  not	
  in	
  use.	
  This	
  
allowed	
  for	
  a	
  1.4	
  yr	
  payback	
  and	
  allowed	
  for	
  a	
  much	
  be8er	
  work	
  environment.	
  The	
  5000K	
  ligh/ng	
  made	
  
reading	
  prints	
  and	
  assembly	
  work	
  much	
  easier	
  than	
  the	
  yellowish	
  HPS.	
  	
  
It	
  helps	
  to	
  sell	
  a	
  ligh/ng	
  retrofit	
  if	
  switches	
  can	
  be	
  added	
  in.	
  Also,	
  do	
  
not	
  forget	
  to	
  calculate	
  the	
  HVAC	
  savings,	
  which	
  can	
  be	
  substan/al.	
  
New	
  ligh/ng	
  can	
  be	
  “brighter”	
  but	
  the	
  foot	
  candle	
  readings	
  may	
  be	
  
lower;	
  be	
  more	
  concerned	
  about	
  the	
  recep/on	
  of	
  the	
  ligh/ng.	
  
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This	
  spreadsheet	
  is	
  a	
  very	
  handy	
  tool	
  in	
  obtaining	
  buy-­‐
in	
  for	
  ligh/ng	
  projects.	
  Be	
  sure	
  to	
  research	
  any	
  
available	
  rebates:	
  they	
  can	
  be	
  very	
  lucra/ve.	
  

K4L67
K27L66
K2:L74
K1;4L26
U/lity	
  Bill	
  Analysis	
  Findings	
  

These	
  2	
  graphs	
  (water	
  and	
  sewer)	
  track	
  together	
  very	
  closely,	
  but	
  they	
  should	
  not.	
  	
  
Sewage	
  should	
  only	
  be	
  charged	
  for	
  water	
  that	
  goes	
  down	
  the	
  drain,	
  not	
  water	
  for	
  
irriga/on	
  or,	
  in	
  this	
  case,	
  water	
  that	
  is	
  being	
  evaporated	
  in	
  a	
  cooling	
  tower.	
  For	
  
the	
  small	
  price	
  of	
  installing	
  an	
  irriga/on	
  meter	
  ($340.00)	
  the	
  sewer	
  bill	
  will	
  drop	
  
at	
  least	
  50%.	
  
Water	
  and	
  Sewer	
  

The	
  sewer	
  bill	
  at	
  this	
  facility	
  is	
  based	
  on	
  water	
  consump/on.	
  At	
  one	
  /me,	
  when	
  the	
  previous	
  
owner	
  had	
  the	
  plant,	
  the	
  water	
  used	
  for	
  the	
  cooling	
  tower	
  and	
  the	
  irriga/on	
  system	
  was	
  
deducted	
  from	
  the	
  total	
  (since	
  this	
  water	
  never	
  went	
  to	
  sewage).	
  The	
  meters	
  below	
  were	
  read	
  
by	
  the	
  County	
  Water	
  and	
  Sanita/on	
  Department	
  monthly	
  so	
  the	
  values	
  could	
  be	
  deducted	
  
from	
  the	
  usage	
  amount	
  reported	
  by	
  the	
  City	
  Water	
  System.	
  

These	
  had	
  not	
  been	
  read	
  since	
  the	
  new	
  owner	
  had	
  purchased	
  the	
  building.	
  You	
  can	
  see	
  this	
  by	
  looking	
  at	
  
the	
  huge	
  increases	
  occurring	
  during	
  the	
  summer	
  months,	
  when	
  the	
  irriga/on	
  and	
  cooling	
  tower	
  load	
  were	
  
at	
  their	
  max.	
  When	
  the	
  Sewer	
  Department	
  was	
  contacted,	
  they	
  did	
  not	
  want	
  to	
  do	
  the	
  readings	
  again	
  and	
  
offered	
  to	
  compromise	
  with	
  a	
  flat	
  rate.	
  This	
  resulted	
  in	
  an	
  annual	
  savings	
  of	
  over	
  $20,000.00.	
  
This	
  school	
  district’s	
  newer	
  elementary	
  school	
  was	
  using	
  more	
  than	
  40%	
  more	
  
energy	
  than	
  the	
  state	
  average,	
  and	
  far	
  more	
  than	
  older	
  schools	
  in	
  the	
  same	
  district.	
  
Met	
  with	
  the	
  Energy	
  Management	
  System	
  contractor	
  and	
  spent	
  the	
  day	
  watching	
  
this	
  system	
  operate	
  in	
  detail.	
  
60	
  	
  Hp	
  Boiler	
  (2)	
  

250	
  Ton	
  Chiller	
  

50	
  Ton	
  Chiller	
  

•  Chillers	
  were	
  operated	
  by	
  a	
  flow	
  calcula/on	
  that	
  did	
  a	
  very	
  poor	
  job.	
  The	
  small	
  chiller	
  
never	
  ran	
  at	
  all.	
  	
  
•  No	
  low	
  OA	
  lock-­‐out	
  for	
  chiller	
  and	
  high	
  OA	
  lock-­‐out	
  for	
  boiler.	
  Large	
  chiller	
  came	
  on	
  when	
  
it	
  was	
  47F	
  outside	
  
•  Only	
  one	
  call	
  for	
  heat	
  would	
  turn	
  on	
  the	
  whole	
  hea/ng	
  system	
  
•  Set-­‐points	
  need	
  to	
  be	
  variable	
  
•  Simultaneous	
  hea/ng	
  and	
  cooling	
  needs	
  to	
  be	
  eliminated	
  or	
  	
  
	
  	
  	
  	
  	
  greatly	
  reduced	
  
30	
  Hp	
  CHW	
  Pumps	
  

CHW	
  Pump	
  Control	
  Pkg.	
  

	
  CHW	
  Pump	
  VSDs	
  (different	
  speeds?)	
  
Pumps	
  had	
  their	
  own	
  control	
  package:	
  they	
  were	
  not	
  
controlled	
  by	
  the	
  EMS.	
  Pumps	
  would	
  not	
  shut	
  down	
  and	
  ran	
  
at	
  different	
  speeds	
  at	
  the	
  same	
  /me.	
  

10	
  Hp	
  HW	
  Pumps	
  
Air	
  Handler	
  

Blower	
  Coil	
  Units	
  

•  Though	
  EMS	
  showed	
  units	
  to	
  be	
  scheduled	
  off,	
  many	
  were	
  s/ll	
  opera/ng	
  
due	
  to	
  hardware	
  communica/on	
  issues.	
  
•  OA	
  should	
  be	
  minimized;	
  why	
  run	
  dedicated	
  systems	
  when	
  the	
  building	
  is	
  
unoccupied	
  
•  Thermostat	
  set	
  points	
  were	
  way	
  too	
  loose.	
  Need	
  to	
  use	
  	
  
	
  	
  	
  	
  	
  	
  ASHRAE	
  standard	
  
EMS	
  (or	
  BAS)	
  U/liza/on	
  
Many	
  /mes	
  an	
  EMS	
  is	
  used	
  for	
  nothing	
  more	
  than	
  a	
  fancy	
  /me-­‐	
  
clock.	
  This	
  is	
  a	
  missed	
  opportunity	
  and	
  waste	
  of	
  money.	
  Control	
  
strategies	
  can	
  reduce	
  energy	
  use	
  significantly.	
  Examples:	
  
•  Op/mum	
  Start/Stop	
  
•  SA/DA	
  reset	
  
•  Sta/c	
  reset	
  
•  HW	
  reset	
  
•  CHW	
  reset	
  
•  Demand	
  Controlled	
  Ven/la/on	
  
•  OA	
  lockouts	
  
•  Humidity	
  control	
  strategies	
  
•  Advanced	
  scheduling	
  
•  Variable	
  override	
  /mers	
  
Poor	
  Installa/on	
  

The	
  heat	
  from	
  the	
  walk	
  in	
  refrigerator	
  and	
  freezer	
  
condensers	
  ejects	
  right	
  into	
  the	
  HVAC	
  condensers.	
  	
  
Condensers	
  are	
  much	
  to	
  close	
  to	
  each	
  other	
  and	
  to	
  the	
  walls.	
  There	
  
is	
  very	
  li8le	
  room	
  for	
  them	
  to	
  dissipate	
  heat	
  effec/vely.	
  
Improper	
  Valve	
  posi/on	
  Example
	
  

This	
  valve	
  was	
  opened	
  a	
  few	
  years	
  ago	
  to	
  compensate	
  for	
  a	
  “water	
  hammer”	
  issue	
  that	
  
occurred	
  by	
  accident.	
  Power	
  readings	
  taken	
  on	
  the	
  pump	
  with	
  this	
  valve	
  open	
  and	
  closed	
  
showed	
  an	
  increase	
  from	
  66KW	
  to	
  82KW.	
  The	
  pump	
  consumed	
  16	
  more	
  KW	
  with	
  this	
  valve	
  
open.	
  Shuung	
  this	
  valve	
  saved	
  $7,140.00	
  a	
  yr.
	
  
Single	
  Point	
  Bulle/ns	
  
A	
  good	
  tool	
  to	
  drive	
  energy	
  awareness	
  
Man-­‐fan	
  example	
  
This	
  man-­‐fan	
  was	
  running	
  24/7	
  though	
  the	
  area	
  was	
  only	
  occupied	
  about	
  90	
  
hours	
  a	
  week.	
  This	
  equates	
  to	
  just	
  over	
  $300.00	
  a	
  year.	
  Remember	
  man-­‐fans	
  do	
  
not	
  lower	
  the	
  room	
  temperature,	
  they	
  are	
  only	
  helpful	
  if	
  you	
  are	
  there	
  to	
  feel	
  
their	
  benefit.	
  How	
  many	
  of	
  these	
  have	
  you	
  seen	
  running	
  in	
  a	
  non-­‐occupied	
  space?	
  
Many	
  man-­‐fans	
  at	
  this	
  facility	
  use	
  more	
  power	
  than	
  this	
  one.	
  
Compressed	
  Air	
  Leak	
  examples	
  
Let’s	
  assume	
  these	
  leaks	
  add	
  up	
  to	
  a	
  1/8”	
  leak	
  (probably	
  very	
  conserva/ve).	
  A	
  
con/nuous	
  	
  1/8”	
  leak	
  costs	
  and	
  unbelievable	
  $7,000.00	
  a	
  year.	
  This	
  is	
  totally	
  
preventable.	
  Maintenance	
  usually	
  repairs	
  these	
  within	
  one	
  day	
  if	
  they	
  are	
  no/fied.	
  
The	
  next	
  /me	
  you	
  hear	
  the	
  hissing	
  sound,	
  remember	
  it	
  sounds	
  like	
  money!	
  
Ligh/ng	
  example	
  
If	
  the	
  ligh/ng	
  override	
  is	
  used,	
  it	
  should	
  be	
  turned	
  off	
  when	
  no	
  longer	
  needed	
  and	
  
not	
  allowed	
  to	
  /me	
  out.	
  Some	
  of	
  these	
  /mers	
  are	
  2	
  hours	
  and	
  some	
  of	
  these	
  zones	
  
can	
  cost	
  up	
  to	
  $15.00	
  for	
  just	
  one	
  hour	
  of	
  opera/on.	
  	
  Knowing	
  your	
  zone	
  helps	
  
prevent	
  the	
  waste	
  associated	
  with	
  turning	
  every	
  zone	
  on,	
  just	
  to	
  make	
  sure	
  you	
  get	
  
the	
  right	
  one	
  (this	
  does	
  happen).	
  	
  
Exhaust	
  fan	
  example	
  
This	
  exhaust	
  fan	
  can	
  cost	
  over	
  $50.00	
  a	
  month	
  to	
  operate,	
  not	
  to	
  men/on	
  the	
  cost	
  of	
  
the	
  condi/oned	
  air	
  that	
  is	
  being	
  pumped	
  outside	
  the	
  building.	
  This	
  fan	
  was	
  not	
  
turned	
  off	
  when	
  produc/on	
  ended.	
  
Space	
  Heaters	
  
!"#$%&'%#(%)*&#)%&-+$#(%.&(')+,5'+,(&('%&3#$4-4M%*&

9'4*&2#*&3+,/.&4/&#/&+L$%&

• 	
  	
  	
  !"#$%&'%#(%)*&*'+,-.&/%0%)&1%&#--+2%.&3+)&('%&3+--+24/5&)%#*+/*6&&
They	
  are	
  a	
  fire	
  hazard	
  
78  9'%:&#)%&#&;)%&'#<#).&
• 	
  	
  	
  =8 hey	
  consume	
  very	
  large	
  amounts	
  of	
  energy	
  
T 9'%:&$+/*,>%&-#)5%&#>+,/(*&+3&%/%)5:&
•  ?8  9'%:&#@%$(&+('%)&%>"-+:%%*&$+>3+)(&1:&$#,*4/5&('%&ABCD&*:*(%>&(+&2+)E&'#).%)&4/&('%&
They	
  affect	
  other	
  employees	
  comfort	
  by	
  causing	
  the	
  HVAC	
  system	
  to	
  	
  	
  work	
  
*,>>%)&F>#E4/5&4(&$+-.%)&3+)&('+*%&24('+,(&('%&'%#(%)*G&#/.&-%**&4/&('%&24/(%)&F'#04/5&#&
harder	
  in	
  the	
  summer	
  (making	
  it	
  colder	
  for	
  those	
  without	
  the	
  heaters)	
  and	
  less	
  
('%)>+*(#(&>%%(&(%>"%)#(,)%&2'%/&('%&2'+-%&)++>&>#:&/+(&1%&2#)>G8&
& in	
  the	
  winter	
  (having	
  a	
  thermostat	
  meet	
  temperature	
  when	
  the	
  whole	
  room	
  
H%)*+/#-&3#/*I&+/&('%&+('%)&'#/.I&.+&/+(&$'#/5%&1,4-.4/5&(%>"%)#(,)%I&J,*(&#4)K+2I&#/.&.+&
may	
  not	
  be	
  warm).	
  
/+(&,*%&>,$'&%-%$()4$4(:8&
Personal	
  fans,	
  on	
  the	
  other	
  hand,	
  do	
  not	
  change	
  building	
  temperature,	
  
	
  just	
  airflow,	
  and	
  do	
  not	
  use	
  much	
  electricity.	
  
To	
  sell	
  an	
  energy	
  project,	
  think	
  like	
  a	
  life	
  insurance	
  
salesman,	
  only	
  backwards!	
  
When	
  selling	
  a	
  policy	
  for	
  $275.00	
  a	
  year	
  it	
  is	
  presented	
  as	
  cos/ng	
  only	
  $.75	
  a	
  day.	
  
When	
  working	
  with	
  energy	
  and	
  jus/fying	
  a	
  project,	
  think	
  the	
  opposite	
  (annually)!	
  	
  	
  	
  
This	
  is	
  especially	
  easy	
  when	
  looking	
  at	
  loads	
  that	
  run	
  24/7,	
  such	
  as	
  an	
  exit	
  sign.	
  

40	
  wa8s	
  –	
  4	
  wa8s	
  =	
  36	
  wa8s	
  *	
  8760	
  hrs	
  (hours	
  in	
  a	
  year)	
  =	
  315360/1000	
  (wa8s	
  in	
  a	
  
kilowa8)	
  =	
  315.4	
  kWH	
  *	
  $.11	
  (price	
  per	
  kilowa8	
  hour)	
  =	
  $34.69	
  a	
  yr	
  in	
  savings	
  

Doesn’t	
  that	
  sound	
  be8er	
  than	
  saving	
  9.50	
  cents	
  a	
  day?	
  
Ques/ons?	
  

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Energy audits in action

  • 1. Session  E4:  Energy  Audi1ng   Energy  Audits  In  Ac1on   Lonnie  Russell,  CEM  
  • 2.
  • 3.    Energy  Audits  in  Ac/on    by    EnergyMan  LLC  
  • 4. Plan  of  A8ack   Building  Energy  Usage:  Non  Industrial Environmental  Control Ligh1ng 20% The goal is to try to make the biggest impact possible with little or no investment. Start with the largest electrical loads and gas users. Includes HVAC and hot water 30% 50% Other
  • 5. Important Question: Why is this operating with no one here? Must do some of audit during non-occupied times These items were found on 24/7 during non-occupied times. Programmable thermostat in override and set to 68F in the summer Boiler 10 Air handlers with a combined horsepower of 68.5
  • 6. This  is  equipment  in  the   cabana;  only  used   seasonally,  but  it  was  all   on;  3  refrigerators  were   empty  and  on,  stove   had  it’s  pilot  light  on   and  hot  water  heater   was    not  turned  off.  
  • 7. The  auditorium  is  a  very  large  space  to  leave  the   HVAC  system  running  when  the  room  is  not  in  use  
  • 9. The  current  IT  PC  policy  is  not  helping  with  PC   power  consump/on,  as  can  be  observed  by  the   hundreds  of  PC’s  that  are  leS  on  24/7.   At  an  absolute  minimum,  the  monitors  should  be  set  to  to  go  to   standby.  Leaving  these  all  on  puts  a  heavy  load  on  the  HVAC   system,  which  may  not  have  been  originally  designed  for  this  large   a  load.  
  • 10. Cost per Year Motor Size 8 cents / kWh 11 cents / kWh 1 kW $611 $964 10 kW $7,008 $9,636 25 kW $17,520 $24,090 50 kW $35,040 $48,180 1 Hp $680 $934 10 Hp $6,796 $9,344 25 Hp $16,989 $23,360 50 Hp $33,978 $46,720 Ini/al  motor  cost  is  only  about  5%  of  the  total   lifecycle  cost,  so  always  buy  an  efficient  motor!  
  • 11. Why  does  equipment  not  get  turned  off?:   •     Lack  of  control  of  building  during  off  hours,  especially  in  buildings  with  mul/ple  users   •       System  was  set  up  that  way  from  the  beginning  and  no  one  on  site  knows  how  to  correct  it.   •       It  has  always  been  that  way  so  no  one  no/ces.   •       We  tried  that  once  but….   •       You  can’t  turn  that  off.  It  may  not  turn  back  on  (my  personal  favorite).   This is not limited to smaller facilities. Here are some sizable loads at a large facility. Chiller and associated equipment Chiller  Primary  and  Secondary   Cooling  Tower  Pumps   pumps   Cooling  Towers  
  • 12. Now  that  the  schedule  is  op/mized  how  do  we  make  our   HVAC  system  more  efficient?   •     Tighten  up  the  building  and  ductwork   •  Control  the  outside  air  (preferably  with  demand  controlled       ven1la1on)  and  Economize,  if  possible   •         Install  VFD’s  where  possible   •         Ligh1ng     •         Energy  efficiency  products   •         Minimize,  or  eliminate  reheat   •   Op1mize  the  set  points  (room  temp,  chill  water,  hot  water,  non-­‐ occupied,  occupied  etc…)   •       ASHRAE  states  that  80%  of  all  occupants  will  be  comfortable   at  temperatures  of  68F  to  74F  in  the  winter  and  73F-­‐78F  in  the   summer  at  no  >  60%  RH.  
  • 13. SCGSAH  1st  year  Results  (opera/onal  changes  only!)   Natural Gas Usage Electricity Usage 16,000 350,000 2008 300,000 2009 Therms KWH 11,000 250,000 200,000 2008 150,000 6,000 Reduc/on  of  51.7%   2009 100,000 Dec Jan Feb Mar Apr May Jun Time 1,000 Dec Jan Feb Mar Apr May Jun Reduc/on  Time8.6%   of  2 Jul YTD Natural Gas Cost YTD Electricity Cost 150000 100000 YTD 50000 Dollars 150000 Dollars Jul 100000 YTD 50000 0 0 2008 2009 Time Reduc/on  of  60.4%   2008 2009 Time Reduc/on  of  18.4%  
  • 14. Building  Envelope  Improvement   This  building  had  many  major  air  leaks  that  needed  to  be  addressed.  Major  leaks  included:   • Exhaust  fans  with  no  dampers  so  they  would  be  wide  open  when  not  running   • Overhead  doors  with  no  seals   • Bathroom  exhaust  fans  that  never  shut  off   • Large  gaps  around  fan  shrouds   • Large  louvers  that  were  open  to  the  outside   Open  Exhaust  Duct   BackdraS  Damper  Installa/ons  
  • 15. Air infiltration repair (Overhead doors) Before   Before  (sunlight  leaking  in)   ASer   Curtain  for   frequently  used  door   Brush  seal   Brush  Seal  
  • 16. Building Envelope and Leaky ductwork examples Faulty    Duct  Insulation Open Roof Access No floor insulation in crawl space Missing    Insulation OA damper stuck open Ductwork insulation in bad shape
  • 17. Negative Pressure from Bathroom Exhaust Fans Bathroom  Exhaust  fans  were  on  24/7.  When  HVAC  equipment  was  shut  down,  these  fans   exhausted  2000  cfm  and  pulled  air  in  from  outside  causing  humidity  to  rise  at  night.   Fan  switches  were  hidden   and  always  leS  on   Sensors  were  installed  to  automate  the  bathroom  exhaust  fans  so   they  would  run  for  15  minutes  when  the  bathroom  became   unoccupied  and  then  shut  off.  
  • 18. Outside  air  control  opportuni/es   Some  places,  such  as  churches  and  auditoriums,  have  high  outside  air  requirements   because  of  the  per  person  ASRAE  ven/la/on  requirements.  This  is  partly  to  prevent  the   “sick  building  syndrome”  issues  that  occurred  when  buildings  did  not  ven/late   adequately  in  the  past.   Sanctuary  Outside  Air  Intake Using  CO2  monitoring,  and  controlling  the  outside  air  intake  based  on  that,  allows  for  proper   outside  air  intake.  Otherwise,  you  could  be  bringing  in  the  outside  air  requirement  for   hundreds  of  people  no  ma8er  how  small  the  occupancy  is.  This  technique  is  called  “demand   controlled  ven/la/on”.  The  price  to  do  this  type  of  control  has  dropped  substan/ally  in  the   last  few  years,  with  CO2  sensors  now  barely  over  $100.00  and  damper  controllers  for  about   the  same.  
  • 19. Demand  Controlled  Ven/la/on   Outside Air Dampers AHUs were initially set at 10% - 15% OA damper open at all times. Especially in the hot humid summers of South Carolina, this can unnecessarily load the system. CO2 sensors were installed and set to open the OA dampers if CO2 levels rise to levels > 1000 ppm.
  • 20. Make  outside  air  your  friend!    Economize  (frequently  called  free  cooling)  for  your   winter  heat  loads.  Able  to  shut  down  all  but  the  air  moving  parts  of  the  HVAC   systems  (chillers,  pumps,  compressors  etc…).   Economizer  possible  for  2309  to  3961  hours.  High  bays  maybe   an  addi/onal  1000  hours.  
  • 21. Equipment  Modifica/ons/Requirements  to  Economize   Outside  air  damper  can   only  be  open  or  closed:   cannot  be  modulated.   Installed   Modulator   Return  air  had  no   damper,  therefore   ra/o  of  return  versus   outside  air  cannot  be   controlled.   Installed   Modula/ng   Damper  
  • 22. Advantages  of  a  Variable  Frequency  Drives  (VFD’s)   HVAC  systems  are  generally  built  for  the  10  hoYest  and  10  coolest  days  of  the  year.  There  is   generally  overcapacity  for  all  other  condi[ons.  VFD’s  offer  the  ability  to  match  the  system  to   the  load,  offering  tremendous  energy  savings  and  extending  equipment  life.     A 50% reduction in flow actually reduces horsepower requirements by 87.5%
  • 23. Pumping  power  is  wasted  (valves  are  par/ally  closed)  making  the  pumps  good  VFD  (variable   frequency  drive)  candidates.  The  pumps  (2)  also  run  con/nuously.  
  • 24. Variable  Frequency  Drive  HVAC  Applica/ons   40  Hp  high  bay  air  handler.   Cooling  Tower  Pump  VFD:  Since  the  small   chiller  only  needs  900  gpm  and  the   exis/ng  pump  supplies  2000  gpm,  a  VFD   was  far  more  efficient  than  a  thro8le   valve  (see  previous  slide).   30  Hp  high  bay  air  handler.     AHU’s:  Original  owner  of  Bldg.  needed  100%  OA  for  the  manufacturing  space.  New  owner  did  not  need   that  so  VFDs  were  used  to  thro8le  these  drives  down  significantly.  This  also  allowed  for  dehumidifica/on   control  (by  moving  the  air  very  slow  and  lowering  the  chill  water  temperature)  and  reduced  load  on  the   chiller  and  boiler.  
  • 25. Reheat  Reduc/on  using  variable  airflow     Fast Airflow Slow Airflow OA damper OA 65F damper Cooling Coil RA damper Filter Air Temp Reheat Coil 50F Cooling Coil Fan Air Temp Original Line-up (simplified with no exhaust): Air moved at max CFM across the cooling coil that had 42F chilled water going through it. This dropped the temperature. This colder air was then passed across a reheat coil that had 180F water going through it. This brought the air to a normal discharge temperature of 55F – 65F. RA damper Filter Air Temp Reheat Coil Fan Air Temp New De-humidification line-up (simplified with no exhaust): Air moved at min CFM across the cooling coil that had 42F 47F chilled water going through it. This drops the temperature significantly, condensing more water therefore reducing humidity. The need for reheat is reduced or eliminated. The reduced airflow helps keep the space from getting too cold, but a little reheat may be required if that occurs. As you can see the low discharge air temperature means the supply air duct definitely has to be insulated.
  • 26. Elimina/ng  reheat  required  the  high  bay   ductwork  to  be  insulated  because  the   discharge  air  temp  would  drop  and   swea/ng  could  occur.  This  was  an   $18,000  investment  with  a  payback  of   about  1  month!  
  • 27. Natural  Gas  Consump/on  Results   Natural Gas Consumption 2500 2006 2007 Dekatherms 2000 2008 1500 228   CDD   1000 500 320CDD   231  CDD   0 1 2 3 4 5 6 7 8 9 10 11 12 Though  Nov08  was   very  cold,  with  a   28%  increase  in   CDD,  gas  usage  only increased  12.8%   Month Natural  gas  consump/on  has  been  the  largest  success  of  our  energy  management  efforts.  Overall  Results:   •   Dekatherms  reduced  by  87.8%   •   Cost  reduced    $239,728  for  a  cost  reduc/on  of    89.2%  
  • 28. Domes/c  Hot  Water   •  •  •  •  •  Electronic  Timers  should  be  installed  on  electric  water  heaters.   Many  facili/es  have  water  heaters  that  are  grossly  oversized   NG  should  be  used  if  available  (Far  less  expensive  to  heat  with  than  electric  resistance)     Tankless  NG  systems  are  ideal  for  low  or  variable  occupancy  applica/ons     Heat  Pump  water  heaters  are  good  for  hot  kitchens  
  • 29. HW  recircula/on  pumps   When  water  heaters  are  turned  off,  their  associated  recircula/on  pumps  need  to   be  turned  off  also.  If  not,  they  will  cause  the  piping  system  to  act  as  a  large   radiator,  removing  heat  from  the  hot  water  tank,  causing  the  water  heater  to  use   more  energy  on  start-­‐up  (to  reach  set  point).  This  energy  loss  is  in  addi/on  to  the   energy  use  to  operate  the  pump  
  • 30. Vending  Misers   •  Install  Vending  Miser  on  soda  machines:     h8p://www.usatech.com/energy_management/energy_vm.php   •  Shuts  down  the  compressor  and  lights  when  people  are  not  in  the   area   •  Can  have  a  payback  of  less  than  one  year   •  Simple  to  install  requiring  li8le  technical  skills   •  Some/mes  soda  vendor  will  supply  for  free   •  Soda  s/ll  stays  cold  
  • 31. Many  opportuni/es  for  vending  and  cooler  misers    
  • 32. Many  drink  coolers   have  very  bad  seal   leaks   “`   A  vendor  supplies  these  coolers  to  this  golf  resort,  but  the  resort  s/ll  has  to  pay  the   u/lity  bill!    These  are  basically  opera/ng  with  the  door  leS  open.  
  • 33. Refrigerated  Water  Fountains   Use  of  a   programmable   receptacle  can   reduce  water   fountain    power   use  by  30%  
  • 34. The  hood  should  overhang  6”  over  the  cooking    equipment.  Either   the  equipment  needs  pushed  back  a  li8le  more  or  extensions  need   installed  on  the  hood.  
  • 35. Dishwasher  sani/zing  heaters,  such  as  these  two  36  kW  models,  can   consume  up  to  30%  of  a  restaurants  total  power  use.  Should  consider   a  NG  unit  or  a  chemical  dishwasher  
  • 36. Dishwasher  exhaust  is  on    when   dishwasher  is  not  opera/ng.  Best  fix  is   an  interlock  
  • 37. Pilot  lights  should  be     shut  off  whenever   possible   Idle  /me  needs  to  be  reduced   whenever  possible  
  • 38. Pilot  lights  are  leS  on  con/nuously   Assume  1,250  BTUs  for  commercial  pilot.  This  is  a  two-­‐fold  savings:  natural  gas  or   propane  to  fuel  the  pilot  and  the  electricity  saved  by  not  having  to  remove  the  heat  with   the  HVAC  system.  A  4  burner  stove  (they  are  usually  larger)  would  require  10  tons  of   cooling  to  remove  the  heat  from  the  pilots!  
  • 39. Walk-­‐Ins     No  curtains     Example  of   a  plas/c   curtain  that   would  work   well  in  the   walk-­‐in   coolers  and   freezers  
  • 40. Ligh/ng  Opportuni/es   Incandescent  Auditorium  Lights   Too  much  aisle  light   Most  painless  energy   project!  Replace   incandescent  exit  signs   with  LED  signs.  About  a  6   month  payback  and  no   complaints!   500  T12  lights  on  at  0100  in  the  morning  in  a  large  library  
  • 41. Many  /mes  hallways  are  over-­‐illuminated.  Rarely  should  a  4  bulb   fixture  be  used  in  a  hallway.  The  Illumina/ng  Engineering  Society  of   North  America  (IESNA)  maintains  that  10-­‐20  fc  is  adequate  for   hallways  and  aisles.  These  were  50  fc  or  higher.  
  • 42. Reduced  Ligh/ng  Plan  on  the  cheap   This  is  an  inexpensive  way  to  secure  ligh/ng  that  does  not  have  switches.  This  example  is  for  high  bay   ligh/ng  (uses  much  more  energy  than  office  ligh/ng).  The  breakers  we  labeled  and  security  was  trained   to  turn  them  off  when  they  are  not  needed.  This  reduced  the  off-­‐shiS  load  by  35  –  50  KW  with  no  capital   required,  just  labeling  and  a  procedure.  The  lifespan  of  the  breakers  was  inves/gated  and  it  was  found   that  they  should  last  over  11  years  if  they  are  cycled  twice  a  day.  
  • 43. Ligh/ng  Upgrades   This  hi  bay  was  converted  from  250w  HPS  to  T8  fluorescent.  32  fixtures  were  replaced  with  16  4’s  and  16   6’s.  This  reduced  wa8age  by  3,242  wa8s  and  HVAC  by  1902  tons.  This  project  was  done  in  conjunc/on   with  installing  switches  that  allowed  for  all  but  6  lights  to  be  off  when  the  space  was  not  in  use.  This   allowed  for  a  1.4  yr  payback  and  allowed  for  a  much  be8er  work  environment.  The  5000K  ligh/ng  made   reading  prints  and  assembly  work  much  easier  than  the  yellowish  HPS.     It  helps  to  sell  a  ligh/ng  retrofit  if  switches  can  be  added  in.  Also,  do   not  forget  to  calculate  the  HVAC  savings,  which  can  be  substan/al.   New  ligh/ng  can  be  “brighter”  but  the  foot  candle  readings  may  be   lower;  be  more  concerned  about  the  recep/on  of  the  ligh/ng.  
  • 45. U/lity  Bill  Analysis  Findings   These  2  graphs  (water  and  sewer)  track  together  very  closely,  but  they  should  not.     Sewage  should  only  be  charged  for  water  that  goes  down  the  drain,  not  water  for   irriga/on  or,  in  this  case,  water  that  is  being  evaporated  in  a  cooling  tower.  For   the  small  price  of  installing  an  irriga/on  meter  ($340.00)  the  sewer  bill  will  drop   at  least  50%.  
  • 46. Water  and  Sewer   The  sewer  bill  at  this  facility  is  based  on  water  consump/on.  At  one  /me,  when  the  previous   owner  had  the  plant,  the  water  used  for  the  cooling  tower  and  the  irriga/on  system  was   deducted  from  the  total  (since  this  water  never  went  to  sewage).  The  meters  below  were  read   by  the  County  Water  and  Sanita/on  Department  monthly  so  the  values  could  be  deducted   from  the  usage  amount  reported  by  the  City  Water  System.   These  had  not  been  read  since  the  new  owner  had  purchased  the  building.  You  can  see  this  by  looking  at   the  huge  increases  occurring  during  the  summer  months,  when  the  irriga/on  and  cooling  tower  load  were   at  their  max.  When  the  Sewer  Department  was  contacted,  they  did  not  want  to  do  the  readings  again  and   offered  to  compromise  with  a  flat  rate.  This  resulted  in  an  annual  savings  of  over  $20,000.00.  
  • 47. This  school  district’s  newer  elementary  school  was  using  more  than  40%  more   energy  than  the  state  average,  and  far  more  than  older  schools  in  the  same  district.   Met  with  the  Energy  Management  System  contractor  and  spent  the  day  watching   this  system  operate  in  detail.  
  • 48. 60    Hp  Boiler  (2)   250  Ton  Chiller   50  Ton  Chiller   •  Chillers  were  operated  by  a  flow  calcula/on  that  did  a  very  poor  job.  The  small  chiller   never  ran  at  all.     •  No  low  OA  lock-­‐out  for  chiller  and  high  OA  lock-­‐out  for  boiler.  Large  chiller  came  on  when   it  was  47F  outside   •  Only  one  call  for  heat  would  turn  on  the  whole  hea/ng  system   •  Set-­‐points  need  to  be  variable   •  Simultaneous  hea/ng  and  cooling  needs  to  be  eliminated  or              greatly  reduced  
  • 49. 30  Hp  CHW  Pumps   CHW  Pump  Control  Pkg.    CHW  Pump  VSDs  (different  speeds?)   Pumps  had  their  own  control  package:  they  were  not   controlled  by  the  EMS.  Pumps  would  not  shut  down  and  ran   at  different  speeds  at  the  same  /me.   10  Hp  HW  Pumps  
  • 50. Air  Handler   Blower  Coil  Units   •  Though  EMS  showed  units  to  be  scheduled  off,  many  were  s/ll  opera/ng   due  to  hardware  communica/on  issues.   •  OA  should  be  minimized;  why  run  dedicated  systems  when  the  building  is   unoccupied   •  Thermostat  set  points  were  way  too  loose.  Need  to  use                ASHRAE  standard  
  • 51. EMS  (or  BAS)  U/liza/on   Many  /mes  an  EMS  is  used  for  nothing  more  than  a  fancy  /me-­‐   clock.  This  is  a  missed  opportunity  and  waste  of  money.  Control   strategies  can  reduce  energy  use  significantly.  Examples:   •  Op/mum  Start/Stop   •  SA/DA  reset   •  Sta/c  reset   •  HW  reset   •  CHW  reset   •  Demand  Controlled  Ven/la/on   •  OA  lockouts   •  Humidity  control  strategies   •  Advanced  scheduling   •  Variable  override  /mers  
  • 52. Poor  Installa/on   The  heat  from  the  walk  in  refrigerator  and  freezer   condensers  ejects  right  into  the  HVAC  condensers.    
  • 53. Condensers  are  much  to  close  to  each  other  and  to  the  walls.  There   is  very  li8le  room  for  them  to  dissipate  heat  effec/vely.  
  • 54. Improper  Valve  posi/on  Example   This  valve  was  opened  a  few  years  ago  to  compensate  for  a  “water  hammer”  issue  that   occurred  by  accident.  Power  readings  taken  on  the  pump  with  this  valve  open  and  closed   showed  an  increase  from  66KW  to  82KW.  The  pump  consumed  16  more  KW  with  this  valve   open.  Shuung  this  valve  saved  $7,140.00  a  yr.  
  • 55. Single  Point  Bulle/ns   A  good  tool  to  drive  energy  awareness  
  • 56. Man-­‐fan  example   This  man-­‐fan  was  running  24/7  though  the  area  was  only  occupied  about  90   hours  a  week.  This  equates  to  just  over  $300.00  a  year.  Remember  man-­‐fans  do   not  lower  the  room  temperature,  they  are  only  helpful  if  you  are  there  to  feel   their  benefit.  How  many  of  these  have  you  seen  running  in  a  non-­‐occupied  space?   Many  man-­‐fans  at  this  facility  use  more  power  than  this  one.  
  • 57. Compressed  Air  Leak  examples   Let’s  assume  these  leaks  add  up  to  a  1/8”  leak  (probably  very  conserva/ve).  A   con/nuous    1/8”  leak  costs  and  unbelievable  $7,000.00  a  year.  This  is  totally   preventable.  Maintenance  usually  repairs  these  within  one  day  if  they  are  no/fied.   The  next  /me  you  hear  the  hissing  sound,  remember  it  sounds  like  money!  
  • 58. Ligh/ng  example   If  the  ligh/ng  override  is  used,  it  should  be  turned  off  when  no  longer  needed  and   not  allowed  to  /me  out.  Some  of  these  /mers  are  2  hours  and  some  of  these  zones   can  cost  up  to  $15.00  for  just  one  hour  of  opera/on.    Knowing  your  zone  helps   prevent  the  waste  associated  with  turning  every  zone  on,  just  to  make  sure  you  get   the  right  one  (this  does  happen).    
  • 59. Exhaust  fan  example   This  exhaust  fan  can  cost  over  $50.00  a  month  to  operate,  not  to  men/on  the  cost  of   the  condi/oned  air  that  is  being  pumped  outside  the  building.  This  fan  was  not   turned  off  when  produc/on  ended.  
  • 60. Space  Heaters   !"#$%&'%#(%)*&#)%&-+$#(%.&(')+,5'+,(&('%&3#$4-4M%*& 9'4*&2#*&3+,/.&4/&#/&+L$%& •       !"#$%&'%#(%)*&*'+,-.&/%0%)&1%&#--+2%.&3+)&('%&3+--+24/5&)%#*+/*6&& They  are  a  fire  hazard   78  9'%:&#)%&#&;)%&'#<#).& •       =8 hey  consume  very  large  amounts  of  energy   T 9'%:&$+/*,>%&-#)5%&#>+,/(*&+3&%/%)5:& •  ?8  9'%:&#@%$(&+('%)&%>"-+:%%*&$+>3+)(&1:&$#,*4/5&('%&ABCD&*:*(%>&(+&2+)E&'#).%)&4/&('%& They  affect  other  employees  comfort  by  causing  the  HVAC  system  to      work   *,>>%)&F>#E4/5&4(&$+-.%)&3+)&('+*%&24('+,(&('%&'%#(%)*G&#/.&-%**&4/&('%&24/(%)&F'#04/5&#& harder  in  the  summer  (making  it  colder  for  those  without  the  heaters)  and  less   ('%)>+*(#(&>%%(&(%>"%)#(,)%&2'%/&('%&2'+-%&)++>&>#:&/+(&1%&2#)>G8& & in  the  winter  (having  a  thermostat  meet  temperature  when  the  whole  room   H%)*+/#-&3#/*I&+/&('%&+('%)&'#/.I&.+&/+(&$'#/5%&1,4-.4/5&(%>"%)#(,)%I&J,*(&#4)K+2I&#/.&.+& may  not  be  warm).   /+(&,*%&>,$'&%-%$()4$4(:8& Personal  fans,  on  the  other  hand,  do  not  change  building  temperature,    just  airflow,  and  do  not  use  much  electricity.  
  • 61. To  sell  an  energy  project,  think  like  a  life  insurance   salesman,  only  backwards!   When  selling  a  policy  for  $275.00  a  year  it  is  presented  as  cos/ng  only  $.75  a  day.   When  working  with  energy  and  jus/fying  a  project,  think  the  opposite  (annually)!         This  is  especially  easy  when  looking  at  loads  that  run  24/7,  such  as  an  exit  sign.   40  wa8s  –  4  wa8s  =  36  wa8s  *  8760  hrs  (hours  in  a  year)  =  315360/1000  (wa8s  in  a   kilowa8)  =  315.4  kWH  *  $.11  (price  per  kilowa8  hour)  =  $34.69  a  yr  in  savings   Doesn’t  that  sound  be8er  than  saving  9.50  cents  a  day?