1. Integrated Retrofits for Federal Projects Dr. Lisa Gartland

2. Integrated Retrofits for Federal Projects Integrated retrofits are tougher to implement in federal projects than in private projects –Politics & bureaucracy Will funding be available this year or next year? What new processes will you need to learn? –Funding sources scattered and variable In-house money, DOE money, other sources Often need to finance different segments of the same project with different pots of money But they’re not impossible

3. Integrated Retrofits for Federal Projects Plan ahead so you’re ready to take advantage of opportunities when they arise –Understand your current loads and systems Measure your loads & audit your systems to find comfort problems, maintenance issues, & energy saving opportunities –Develop a wish list Research specifications and prices for the technologies you want to incorporate –Plan out the optimal order of attack If possible, you’ll want to reduce loads first, improve systems second, & replace chillers last

4. Integrated Retrofits for Federal Projects In This Presentation Federal integrated retrofit projects –Federal Reserve Bank of Boston Business as usual –Hurley Building Dealing with catastrophe –Lindbergh Field International Airport Building expansion

5. Federal Reserve Bank of Boston The Business as Usual Integrated Retrofit Designed & built 1972-76 33 story tower 5 story low-rise 1,130,000 square feet Steel construction with glass & aluminum facades Steam heating Electric powered chiller cooling

6. Federal Reserve Bank of Boston Project Objectives & Logistical Issues Energy efficiency, utility cost reduction Improvement of lighting & mechanical systems Improved environmental management, CFC compliance Bank Security On-going operations Time constraints Space constraints Future flexibility Facility location John Yahoodik Federal Reserve Bank of Boston Rick Dorricott Energy Investment, Inc.

7. Federal Reserve Bank of Boston Building Improvements Chiller replacement –Originally used 3 York 1200 ton, 0.82 kW/ton, R-500 refrigerant (CFC/HCFC blend) –Replaced with 3 Carrier 1200 ton, 0.56 kW/ton, HFC-134a refrigerant System improvements –Automated economizers, premium efficiency motors, VFD’s on cooling towers, various controls & automation Lighting upgrades –T-8 fluorescents, specular reflectors, LED exit signs, incandescents changed to fluorescents

8. Federal Reserve Bank of Boston Integrated Energy Program Other energy efficiency improvements help pay for chiller replacement for CFC compliance Shorter overall program payback period

9. Federal Reserve Bank of Boston Project Timeline 8 months for engineering analysis, 18 months for project approval, 21 months to purchase, design & build 4 years total to carry out project!

10. Federal Reserve Bank of Boston Project Results Expect to save 5,300,000 kWh a year Annual $730,000 savings Switch to HFC-134a, no phaseout Improved lighting and HVAC systems Only a 5 year project payback period Used the chiller replacement project as an excuse to add new technologies

11. Hurley Building, Boston, MA From Catastrophe to Integrated Retrofit Built in 1971 Poured concrete construction Department of Employment & Training and Group Insurance Commission 6 floors office plus 2 level parking garage 340,000 square feet office, 15,000 square feet computer

12. Hurley Building Project Scenario & Challenges Catastrophic failure of absorption cooling plant in 1992 Rising cost of steam/water, ~20% increase from 1989 to 1992 Expensive maintenance contract for systems Computer room cooling units at end of life Need to restore cooling capabilities before the summer of 1993 Fuel switch from steam to natural gas Need to replace heating & hot water systems Space, weight and routing constraints of 6th floor mechanical room B.J. Mohammadipour Bureau of State Office Buildings

13. Hurley Building HVAC System Changes Chiller/heaters installed for main cooling and heating –2 York 600 ton absorption chiller/heaters –natural gas fired –require hydronic coils to allow air handling units to use hot water instead of steam Water heating –kitchen and lavatory hot water supply –converted from steam to natural gas fueled Computer room cooling –single DX chiller used for wintertime cooling –tied to chiller/heater to meet summer loads

14. Hurley Building Other Improvements Lighting improvements made in 1992 –new reflectors, lamps and ballasts –light levels maintained or improved New maintenance contract –Renegotiated scope of maintenance contract –Additional maintenance contract for new absorption chiller/heaters –Total maintenance costs reduced by at least $126K annually

15. Hurley Building Integrated Energy Program Lighting improvements and new maintenance contract help pay for HVAC system changes

16. Hurley Building Financed by Many Sources Chiller/heater cost –$565,000 purchase cost paid up front –$472,000 installation costs financed over 3 years –$50,000 rebate from Boston Gas Computer room, water heater, EMS system, hydronic coils financed over 3 years Lighting improvements funded by Boston Edison Company in 1992

17. Hurley Building Project Results Chiller/heaters fit into mechanical room Utility savings of ~ $300,000 annually Maintenance savings of ~ $140,000 annually Replacement of steam with natural gas Improved building comfort from better balancing and EMS system controls Potential catastrophe diverted by advance knowledge and preparation Creative negotiation & financing made this project come together

18. Kansas City International Airport The Building Expansion Integrated Retrofit Pre-cast concrete frame construction, thermal glass Main hours 5 am to 11 pm –365 days a year, 24 hrs a day About 1 million square feet –3 airport terminals –1 administration office Built from 1969 to 1971 Airport expansion being planned

19. Kansas City International Airport Project Scenario & Challenges High electricity demand charges Two 2750 ton chillers, never run 2nd chiller, 1st chiller run often at low part-loads Chillers use CFC refrigerant Controls shot, using manual operation 48-49°F discharge water temperatures, not meeting the design 42°F temperature Retrofit phases in wrong order –cooling system redesigned –EMCS & heating system installed –building retrofits & load reductions last, if ever 2 month shut-down period in January & February in which to do most of phase one Must replace all chillers, cooling towers, pumps & piping without disrupting service Michael Glasker, P.E. George Butler Associates, Inc.

20. Kansas City International Airport Cooling System Changes Three 1500-ton electric chillers –more flexible staging capability –R-134a refrigerant, 0.65 kW/ton at full load, saving 0.25 kW/ton! –Now meeting 42°F discharge water temperatures Three new 2-cell cooling towers with 2-speed fans New primary/secondary pumping & piping for operating flexibility New Johnson Controls EMCS –Remote start/stop capability, tracks temperatures on computer, alarm points built into system –Still chose not to have automatic operation

21. Kansas City International Airport Upcoming Building Load Reductions Extensive building remodeling planned in older terminals Energy efficiency measures will reduce building cooling loads –new energy efficient lighting –new air handler units with economizers More flexible cooling plant design will operate efficiently at these lower loads

22. Kansas City International Airport Integrated Economics as of Spring 98 Second phase measures reduce project payback Third phase measures should reduce overall payback even further

23. Kansas City International Airport Project Results No longer using CFC refrigerants Higher efficiency chillers save ~0.3kW/ton 3 smaller chillers, instead of 2 larger chillers –running closer to full-load capacities for higher efficiencies –meeting 42°F design water discharge temperature Automatic operation using EMCS More flexible cooling system will work more efficiently with upcoming terminal retrofits Used airport expansion cash to finance extensive retrofit of cooling systems New cooling systems are flexible so they’ll efficiently serve future airport loads

24. Integrated Retrofits for Federal Projects You can overcome federal bureaucracy to perform an integrated retrofit! Start work now to: –Study your building loads & systems –Develop your wish list –Learn about financing options You can turn your situation - even if it’s catastrophic - into an integrated retrofit