retro-commissioning: energy hero in plain sight · 1. track : benchmarks, trends, kpis 2. tune...

Retro-Commissioning: Energy Hero In Plain Sight

Kevin Gombotz, PE

10-5-2017

11/10/2017 Copyright Envinity, 2015 1


Kevin Gombotz, PE• Envinity Building Energy Solutions• Vice President• Treasure Hunter


$-

$100,000

$200,000

$300,000

$400,000

$500,000

$600,000

Hospital Energy Cost

Before

After

What does a hero project look like?

Direct Cost: $40,000Savings: $85,000 / yr (15%)6 months duration6 month paybackPaid off in same fiscal year 2 days per month staff time!


Old woman or young woman?

RCx: fresh set of eyes to• Spot opportunity• Solve problems• Serve the mission

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Before 1960 1960's 1970's 1980's 1990's 2000's

kbtu

/sf

Energy Use By Age


Even new hospitals are slacking!

10% Energy decrease

7% Energy increase

Credit: 2007 and 2012 CBECs building survey, EIA

Hospitals

All Commercial Buildings


Are LEED hospitals any better?

Average Payback: 2.5 yearsAverage Savings : 22%Total Cost Savings: $1.8M

0%

5%

10%

15%

20%

25%

30%

35%

Hospital 12012

Hospital 22014

LEED certified

Hospital 32013

Hospital 42006

LEED certified

Hospital 52003

Hospital 62009

LEED certified

Annu

al S

avin

gs

RCx Savings 6 New Hospitals

LEED

LEED

LEED


LEED isn’t leading

Only 5% of LEED hospitals are Energy Star certified.

Credit: USGBC and Energy Star online certification listings

RCx can be the difference


• 73 beds, specialty surgery• 146,000 square feet• Built 2012

• Commissioned by 3rd Party• Retro-commissioned by 4th Party!• 15% cost savings, 6 month payback

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Energy Star Score

Before Retro-Commissioning

After Retro-Commissioning

Wellspan Case Study - Rehab Hospital

$-

$100,000

$200,000

$300,000

$400,000

$500,000

$600,000

Energy Cost 2012 Hospital

Before Retro-Commissioning

After Retro-Commissioning

Is it worth fixing?

• Build trust through RCx• Get recognized by AHA• Get consistent funding


x 500,000 sf = $2.5M investment

x 25% savings

x 5 Year Payback = $5/sf upfront investment

$4/sf utilities

RCx lays foundation for $$$


5%

25%

70%

Path to 30% Reduction

Retro-commissioning

Capital Energy Projects

Improved Use

Worth fixing? … Joint Commission

RCx Targets JACO Compliance Issues• Temp and humidity • Room pressure requirements (Tissue test)• Final filter condition


Worth fixing? … Reduce work orders

RCx Reduces • Hot/cold calls• Sweating windows• Building pressurization• Freeze stat trips• Unplanned failures (short cycling, hunting, etc)• Angry surgeons


RCx Process Steps


1. Track : Benchmarks, Trends, KPIs2. Tune Procedures and Setpoints3. Find and Fix Faults4. Improve Controls Programming5. Increase Scheduling6. Re-engineer Airflows for Current Use

Best

Pay

back

1. Track : benchmarks, trends, KPIs

E.g. Tracked kW/ton and CHW load improvements through BAS trend data

2. Tune procedures and setpoints

E.g. Reduce condenser setpoint for improved part-load performance; increased economizer setpoints


Procedures : Let the leader lead

Lag Boiler 15 KW less$9,500 / yr just to make it the “lead”

Electric Boiler, Sterile Processing


Setpoints

20 KW less chiller power • Turned knob to lower tower setpoint

• 1 hour fix• $5,000 per year

3. Find and fix faults

E.g. Repaired OA damper actuator on RTU serving Sterile Storage


Find and fix faults

Inlet Temp 55F

8degF waste x 1.085 x 2000 cfm / 12000 = 1.5 tons needed3 tons supplied$2000/yr savings

4. Improve controls programming

E.g. add SAT reset with zone demand, pump pressure reset


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MBH

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Tons

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KW

Change VAV sequence to “dual max” to allow lower heating min:• 4 hours programming• $17,500/yr

10 KW $9,000/yr electric

15 tons $4,500/yr chilled water

150 MBH $5,000/yr reheat

Programming

5. Increase scheduling

Scheduling was good, but only 5% of total air. Needed to enhance. Therapy room needed a “walk through” mode

E.g. Provide unoccupied mode Offices, Kitchen, Outpatient. Respond to operator feedback to refine mode.


Scheduling

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KW

Total fan powerLobby Air Handler:• Zone level schedule• 20 hrs programming• 5 KW daily average reduction• $7,000 / yr savings

6. Engineer airflows for current use

Reduced 9,500 cfm of SA (11%) from heating minimum by providing dual-maximum control. Modified damper and reheat sequencing.

Further opportunities to re-engineer minimum flows for current use and code requirements.


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Airflow

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Avg

Vavl

e %

Reheat

Engineer airflows to current code

Blood bank example:• Designed at 30 ACH• Left at 30 ACH• Current code 6 ACH• 4500 cfm reduction• 4 hr change• $11,000 / yr savings

Fan Energy: $ 6,504 Chilled Water: $ 1,831 Reheat: $ 2,807 TOTAL SAVINGS: $ 11,142

RCx Process


Interview staff about opportunities and trouble callsDocument controls settings and enable trendingSurvey drawings and controls, follow-up with inspectionWork closely controls tech and mechanic to modifyEffective communication with maintenance teamDocument Issues Log, BAS Change Log, and trip reports


Owner’s strategy


BTUs

Find a champion – is it you?

Build a team


BTUs

Tips for the owner


Appoint Internal Cx Leader and TeamFind a CoachLeverage Controls Service AgreementSet Aside Repair BudgetInitiate a HVAC Trouble Tracking Process with StaffProvide Offsite BAS Access for Consultant / Analyst

Most Important Tip!


Don’t save too much!!!

5%

25%

70%

Path to 30% Reduction

Retro-commissioning

Capital Energy ProjectsImproved Use

Until you get the $$ for Capital Projects!

Thank You.

Questions?Kevin Gombotz, PE

Vice President of Commercial Energy Services

[email protected]


mailto:[email protected]

More Examples


Leaking valves

Broken dampers

Valve conflicts …. Like “gas and brake”

Follow the work orders

“But

ton

push

”

One day RCx effort initiated $60,000 / yr savings

Benchmarks Show Potential


Clinical Quality Upper 10%

60

Main Hospital Current

RehabCurrent

5710% savings

~$50,000 / year

retro-commissioning: energy hero in plain sight · 1. track : benchmarks, trends, kpis 2. tune...

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