I recently gave this presentation at the World Energy Engineering Congress In Washington DC (Oct13) and it was well received. It shows a "big picture" approach and gives plenty of real world examples.
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
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.
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
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.
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&.+&/+(&$'#/5%&1,4-.4/5&(%>"%)#(,)%I&J,*()K+2I&#/.&.+&
may
not
be
warm).
/+(&,*%&>,$'&%-%$()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?