HVAC Replacement Case Study

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Presentation transcript:

HVAC Replacement Case Study Project Review of the MN Power Cloquet Service Center VRF research project.

Building Overview Built: Original HVAC System: 1982 Original HVAC System: Electric forced air with air conditioning Building size and capacity: 19,500 total Sq. Ft. 9,650 Office Space 1 Story MP Service Center

HVAC Replacement HVAC Replacement System is 28 years old Internal Duct insulation Project Scheduled for October 2010 Regular HVAC designer used for project Replace the ductwork Initial Replacement Quote – Replace with similar spec. equipment The project is currently undergoing a recommissioning to correct problems with comfort and efficiency. Photo By: ductworks.com/wp-content/uploads/2010/03/air-duct-insulation-300x225.jpg

Energy Efficiency Request Energy Efficiency Group Requested Higher Efficiency HVAC Management approved Building Manager Agreed New type of system – Leading edge technology for the area. The System - Variable Refrigerant Flow Air Source Heat Pumps. Benefits Smaller piping High Efficiency Heating and cooling Limited Ducting Photo By: http://www.buildings.com/techindepth/vrf

Proposals 1st Proposal replace system with similar system. Rejected by building owner required higher efficiency system. Request for High efficiency VRF system by the customer. Rejected by the designer said it will not work in Northern MN. 2nd Proposal similar system in addition to high efficiency System Rejected proposal because of the cost and 2 complete systems were not required. 3rd Proposal for a stand alone VRF system. Requested by facilities manager and energy efficiency group.

Challenges Additional Equipment Ventilation System Duct work was removed Make up air Heat pumps spread around the building Power Requirements Expanded Control System Communication lines to individual heat pumps and thermostats Additional Cost Replacement cost for similar system approx. $65,000. New system $100,000 https://www.pinterest.com/chels1292/hvac/

Design Phase Customer Concerns Energy Efficiency Cost (Install only one system) Controllability (BAS, Energy Efficiency) Contractor Concerns Will it Work in Northern MN (Customer Satisfaction) Customer Wish List vs. Standard Practices (HRV’s instead of a MAU) Cost (Initial, Long term and Call backs) Technical (New system design, what size, how to control…)

Building Comfort and Technical Issues Problem maintaining temperatures. Very low humidity from over ventilation Dry floor drain traps (sewer smell) Drafty feel when heat pumps are not running System will not auto switch from AC to Heat System will fight itself AC vs Cooling (both on) Communication and control issues Master and Slave control issues. (Slave set as master)

Design/Installation Issues Note: Some of the design issues noted may have happened after initial Installation. Bathroom exhaust only ventilation causes problems in wild plenum No Dampers on the HRV’s in the office areas HRV Ducting (Balanced flow, Flexible ducting) Schedules and settings Occupancy Variables (all units are on or off) Garage (Master of Bathrooms) BAS Controls, Manufacturer and contractor controls (who commands Who) IT Room Heat Recovery ( Was never achieved)

Costs Initial Design Costs Replacement cost Initial replacement costs $130,000 Call backs (numerous mechanical and control calls) Consultants to help with the repairs. $20,000 Contractor Costs to implement mechanical Fixes $35,000 Contractor to fix the controls $15,000 Other Costs Higher energy costs Local personnel time and comfort http://wildmorrealty.com/wp-content/uploads/labor-cost.jpg

Could this have been prevented? Design Phase Goal requirements agreed upon. VRF system for 100% heating and cooling (can it be done?) Programing, schedules and control Ventilation Requirements Energy Efficiency Maintenance schedules and equipment Change orders ( Impacts of changes ) https://www.yos.org/sites/www.yos.org/files/assets/prevention.jpg

In-Depth Design How much more will it cost? How much longer will it take? Do customers see the value up front? Will better design result in less call backs? Will we have more energy efficient buildings? Will In-Depth design with the Contractor, Building Owner and Maintenance reduce call backs? http://www.mavinconstruction.com/wp-content/uploads/2012/09/pre-construction-meeting.jpg