July 2010 SUMMARY ENERGY EFFICIENT HENDERSON … · AUSTIN, TEXAS 78774 PHONE: (512) 936-9283...

July 2010

SUMMARY ENERGY EFFICIENT

HENDERSON ELEMENTARY SCHOOL TECHNICAL ASSISTANCE REPORT

FORNEY ISD FORNEY, TEXAS

MS. JULINE FERRIS PROGRAM SPECIALIST

STATE ENERGY CONSERVATION OFFICE COMPTROLLER OF PUBLIC ACCOUNTS

111 EAST 17TH STREET AUSTIN, TEXAS 78774 PHONE: (512) 936-9283

ESTES, McCLURE & ASSOCIATES, INC. ENGINEERING AND CONSULTING

3608 WEST WAY TYLER, TEXAS 75703

PHONE: (903) 581-2677 [email protected]

James D. McClure, P.E. Texas P.E. 30580 Estes, McClure & Associates, Inc. Registration Number F-893

TABLE OF CONTENTS 1.0 EXECUTIVE SUMMARY

2.0 DISTRICT ENERGY AND COST PERFORMANCE

3.0 CURRENT MAINTENANCE PROGRAM

4.0 PREVENTIVE MAINTENANCE SCHEDULE (HVAC)

5.0 ENERGY MANAGEMENT CONTROLS

6.0 REPLACMENT PROJECTS

7.0 ON-SITE TRAINING O&M

APPENDEICIES

A. Preliminary Energy Assessment Agreement

B. Aaon RK Series Manufacture’s Installation Instructions

C. Aaon RK Series Manufacture’s Users Information Manual

D. Carrier FB4 Manufacturer’s Instructions

Estes, McClure & Associates, Inc. Engineering and Consulting

1.0 EXECUTIVE SUMMARY

The Technical Assistance is provided by the State Energy Conservation Office (SECO), a division of the Comptroller of Public Accounts of the State of Texas. This service assists school Districts in taking basic steps toward energy-efficient facility operation. Active involvement by the District in the partnership is critical in developing a customized blueprint for energy efficiency.

One of the first steps toward energy-efficient school operation is identifying the current energy performance of District facilities. An energy performance summary is included in Section 2.

Successful school energy management programs include the following: Identify the Need – District Energy Evaluation Appoint an Energy Manager & Provide Training Adopt a District Energy Policy Write an Energy Management Plan & Present to the School Board Implement Energy Accounting System Conduct Energy Audits Establish Energy Committees Adopt Building Operating Procedures & Guidelines Involve School Personnel & Students Obtain Publicity Create Competition & Incentives Communicate Success Give Personal Contact and Feedback from Energy Accounting Energy Procurement

This Technical Assistance Report addresses the following specific requirements:

Current Maintenance Program

Preventive Maintenance – HVAC

Energy Management Controls

Replacement Projects

On-Site Training O&M

James D. McClure, P.E., and Javier Garcia of Estes, McClure & Associates, Inc. (EMA) visited the District and met with Mr. Greg Buchannan, Maintenance/Energy Director. Your personal contact at SECO is Ms. Juline Ferris (Phone: (512) 936-9283); your contact at Estes, McClure & Associates, Inc. is James McClure, P.E., and Gary Bristow, P.E. (Phone: (903) 581-2677). Please call us if you have any questions or comments about this report or other energy management issues. Forney ISD is located in a high development growing area. Forney ISD has a formal energy management program and an energy manager.

The Energy Use Index (EUI) data EMA has for 2008-2009 averages for North and East Texas schools shows 53,440 Btu/ft²-yr for elementary schools and 60,173 Btu/ft²-yr for secondary schools. Of the nine Forney ISD elementary schools seven are below the regional average and the two high schools are above the regional average. The lower the EUI (Btu/ft²-yr) the more energy efficient. The following is a brief summary of specific technical assistance approved by SECO for Forney ISD.


Current Maintenance Program (See Section 3)

Energy Manager is now Maintenance/Energy Manager. This provides unique opportunities for Forney ISD.

Maintenance/Energy building and office located in new building near the new north high school.

New maintenance director scheduling preventive maintenance and also doing during regular year and not waiting for summer.

Cleaning of Henderson HVAC units now underway.

Filters are MERV 6 and replacement service is contracted.

No established PM plan or schedule for HVAC. Preventive Maintenance Schedule (HVAC)

Section 4.0 this report provides summary of PM plan for HVAC. Also provided is list of Henderson Elementary HVAC, location, and PM recommendations based on manufacturer’s recommendations and ASHRAE’s recommendation for systems.

Energy Management Controls

Section 5 of this report provides observation of EMCS and control settings/systems for Henderson Elementary.

Retrofit Projects

Section 6 of this report provides several retrofit projects evaluated for Henderson Elementary. Estimated Benefit for Henderson Elementary, Forney ISD

Preventive Maintenance

HVAC Energy Savings : $3,690/yr., 30,000kwh

Extend life of equipment while maintaining comfort, efficiency, and clean air. 5 year life extension above ASHRAE life would save $38,960 in interest cost each year of delay of purchase of new equipment.

Est. Cost = $12,865/yr.

Est. Savings Total = $42,650/yr.

EMCS

Energy Manager already very knowledgeable of control system and operations.

Reset set-point on cooling lockout should improve comfort under certain operating conditions. Set outside air on time-of-day schedule as well as CO2 demand control.

Est. Kwh/yr. saved = 7425

Est. $/yr. saved = $1,000

Est. cost = $120

Retrofit Projects

Replaced gym metal halide lighting with energy efficient T5 HO fluorescent lighting and occupancy sensors to control lighting.

$/yr saved = $603 Kwh/yr saved = 4902 Estimated cost = $6,000


Other Similar Campuses

Forney ISD has several other very similar elementary schools with same type HVAC equipment. Preventive maintenance and lighting projects accomplished at these campuses as recommended for Henderson Elementary will multiply the opportunity for savings and life extension of equipment.

On-Site Training

Informal on-site training will be provided for building operator and maintenance staff in conjunction with delivery of this Technical Assistance Reports (See Section 7 for outline/plan).

Appreciation

EMA appreciates the opportunity to provide the information in this report. Our intent is to be helpful and responsive to questions that were asked. SECO is commended for sponsoring and providing this assistance program for FISD and other school districts.

Please call to discuss or ask questions. Thank you.


2.0 DISTRICT ENERGY AND COST PERFORMANCE

The energy use performance or energy use index (EUI) and the energy cost performance or energy cost index (ECI) is provided below. Other detailed data is shown on the Base Year Energy Consumption History table provided in Appendix of this report.

The energy cost index is a valuable tool for comparing the energy cost ($) of different schools and campuses in a given area. The lower the EUI the more energy efficient. The energy use index allows for comparison of schools on a quantity (BTU) basis. Since the cost of electricity varies by school and natural gas is so much less than the cost of electricity, this index is a true value of the actual energy use on a square foot basis. The energy cost index (ECI) and the energy use index (EUI) are determined by the following formulas.

ECI = Annual Electrical Cost + Annual Natural Gas Cost

Total Area of School

EUI = Annual Electrical BTUs + Annual Natural Gas BTUs

Total Area of School


3.0 CURRENT MAINTENANCE PROGRAM The maintenance building is located at 6170 N. Mason Blvd., Forney, Texas 75126. The facility is near the new high school. Mr. Greg Buchanan has recently been named Maintenance/Energy Manager. Previously Mr. Buchanan was the District’s Energy Manager. He now serves as head of maintenance and energy. In addition to being Forney ISD’s Energy Manager, Mr. Buchanan served in the U.S. Army and his background in maintenance and training received is valuable to Forney ISD.

The district does not have cost break-out information of different types of maintenance (eg. emergency, reactive predictive, preventive, or by HVAC or other categories).

Mr. Buchanan since taking over maintenance has implemented 6 a.m. to midnight Monday-Friday maintenance work schedule. The goal is to not delay much of the maintenance until summer and also control the amount of work backlog including summer time when school is out. For example, recently all district fire alarms were cleaned and preventive maintenance accomplished on water fountains prior to school out for the summer.

Mr. Buchanan’s goal is to implement Preventive Maintenance for Forney ISD. The Preventive Maintenance Schedule – HVAC section of this report should be helpful in that planning/implementation and was requested.

The cleaning process of HVAC systems has now been initiated. During the on-site visit to Henderson Elementary, the coils were being cleaned.

Mr. Buchanan reported that all filters are MERV 6 media type (non pleated). Filter replacement is accomplished by an outside contractor. Next year a test is planned for a campus with clean coils. One half will have 2” MERV 7 pleated filters and the other half non-pleated. There is much development in Forney, Texas requiring monitoring frequency of filter changing.

The following are recommended to assist in monitoring and tracking maintenance costs and evaluation of systems especially as they begin to age.

Work orders identify type of maintenance (eg. emergency, scheduled, reactive, preventive) and type system (eg. HVAC, plumbing, etc.)

Track outages for re-occurring trends (eg. HVAC not working, etc.)

Track work order results to cost reporting

Track delays (eg. waiting for parts, tools/equipment, etc.)

Compare in-house maintenance costs (labor and materials) to sub-contract.

Train all departments or groups to function as a team. For example, security, energy, integrated-pest-management, maintenance, custodial, and IT understanding others issues to aid in coordination and reporting.

Define expectations and goals. Include potential life extension of equipment.

Focus initially on priority of needs/costs and high energy using systems.

Define/separate maintenance tasks that frequency is one year or less.

Identify main equipment to keep building occupants comfortable and secure (eg. HVAC, electrical panels, security, fire alarms, sprinkler systems, etc.).

Conduct inventory (eg. data plate, manufacturer, age, supplier, O&M, etc.).

Identify life expectancy as well as age. Once know or determine life cycle can set-up budget/plan for PM or replacement.

Identify items causing high outages and emergency calls.

Set-up budget for primary equipment item’s maintenance. Compare doing within district to


outsourcing.

Create folder/file for each primary equipment (eg. O&M manual, PM schedules, service records, supplies for parts or services, warranties, etc.)

Conduct a HVAC Master Plan showing type equipment, size quantity, refrigerant, ventilation standard, method outside air control, condition, age, ASHRAE median life, anticipated life extension with year of expected replacement, budget estimate, and priority & replacement.

The savings from a maintenance program is a function from where one is starting. For example, with already reasonable energy savings, the benefits may be more of life extension of equipment, more comfortable occupants, reducing outages, etc. rather than instant large energy savings.

The Preventative Maintenance Schedule – HVAC section of this report will also be helpful in establishing PM program, tasks, and schedules.

Understanding where energy is consumed in a school is also beneficial in prioritizing initial focus. The following is typical elementary school energy usage in the Forney area. Electric Use by Category

Cooling 38% Air-Handling 14% Lighting 24% Computers 11% Kitchen 6% Miscellaneous 7%

Natural Gas Use by Category

Space Heating 80% Kitchen & DHW 20%


4.0 PREVENTIVE MAINTENANCE SCHEDULE (HVAC)

Preventive maintenance (PM) is a sequence of planned and budgeted time-based actions designed to detect, preclude, or mitigate degradation of a system or its components. Routine inspection and subsequent adjustment or maintenance of system components is beneficial in keeping the system operating within its optimum performance parameters. Preventative maintenance also helps retain the ability to provide the energy efficiency, thermal comfort, and indoor air quality intended. Maintaining the system in new or nearly new condition may extend component/equipment life as well as keep energy efficiency in control. Reduction of down time has been shown to be a benefit of PM. The return on PM varies and savings, if any, are dependent in part on existing conditions and equipment age.

The American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc. (ASHRAE) has developed ASHRAE Standard 180, Standard Practice for Inspection and Maintenance of Commercial Building HVAC Systems. The intent of the ASHRAE standard is to guide maintenance of HVAC systems because the maintenance information often provided by manufacturers applies only to the specific component that they provide rather than to the entire system. The ASHRAE Standard provides their recommended minimum level of preventive maintenance. Other standards, guidance documents, manufacturer’s instructions, local conditions, applications, etc. may establish more specific or rigorous requirements. Manufacturer’s instructions should be used in conjunction with ASHRAE.

The following are some of the tasks or actions needed to implement a PM program.

Establish Goal: Preserve the condition of the HVAC to maintain or extend median life, provide intended thermal comfort, energy efficiency, and indoor air quality.

Inventory of Equipment and Systems: Make detail list of components. Use this initial detail list to establish any unacceptable system conditions or indicators, maintenance tasks needs, and future inspection frequencies.

Develop Preventive Maintenance Plan: Include required tasks, identify party responsible for performing these tasks, the authorizing party, documentation of the completed tasks and subsequently monitor the results. The PM plan should also develop budgets for the work and obtain approval from responsible authority and sources. Review time and skill level needed.

Establish indicators of conditions that indicate or could eventually result in performance degradation or failure.

Establish tasks to include on-site inspection and physical assessment of components and system. This may also measurement of operating parameters from the central control or energy management control system. Maintenance tasks should include adjustment, service or replacement.

Frequency of inspection, monitoring, and PM tasks need to be established. It is critical to be able to predict when a task should be done and not make the time-based work an absolute. The ASHRAE Standard 180, manufacturer’s recommendations, local conditions, climate related and operational conditions, local experience and observations may be used to determine frequency.

Determine if equipment has been in service beyond useful life.

Observe for conditions outside of HVAC that are resulting in failure, performance decrease, or increased maintenance frequency. For example some outside HVAC conditions to look for include vandalism, significant dust or contaminants coming onto the property from other sources, etc.


Documentation and record keeping for tracking.

Include periodic review and revision of the PM plan.

One of the goals of today’s PM programs needs to be getting energy savings standardized as part of maintenance. Getting energy efficiency into maintenance job planning criteria and standards is helpful.

The table at the end of this section provide HVAC equipment list for Henderson Elementary. Combing manufacturer’s maintenance data and ASHRAE’s system data results in the Preventive Maintenance and maintenance activities for the HVAC at Henderson Elementary. Feedback From EMA Survey

EMA recently conducted a survey to get feedback from Texas ISD’s on EMCS and Preventive Maintenance. The following is the response so far from 16 school districts. It is provided for informational purposes.

Survey Question Response Percent

Yes No

1. Does your district utilize EMCS? 100% 0% 2. If yes to question 1, does your district have more than one brand

(mfg) of EMCS in use? 73.3% 26.7%

If yes, does it create any problems (10 responded) 7 Yes 3.

How are the EMCS in your district operated/who operates them?

Central (one person) 68.8%

Maintenance, Technician 25.0%

Energy Manager 68.8% 4. How does your district handle repairs, etc. of the EMCS and

components?

In house staff 56.3%

Outside contractor 43.8% 5.

Does your district have a preventive maintenance program (PM)? 75.0% 25.0% 6. If answer yet to above question, do you subcontract any parts of

preventive maintenance? 33.3% 66.7% 7. If you answered yes to having a PM program, is you PM;

A regular part of maintenance 36.4%

Handled separately 63.6% 8. If you answered yes a PM program, does your district have a

written PM plan defining tasks, frequencies, and assignments? 58.3% 41.7% 9. Has your district standardized on one type of HVAC system? 26.7% 73.3%

10. Does your district have an HVAC master plan with needs, priorities, and budgets? 60.0% 40.0%


Gas/Electric RTU's (AAON)

Maintenance Activities Frequency

Inspect blower, evaporator coil, and filter for obstructions and proper air flow. Monthly

Before heating season, inspect all flue product carrying areas and main burner. Do not clean gas burners or heat exchanger. Dirty burners or heat exchanger indicates faulty unit operation. Contact and AAON Service Representative. Annually

Lubricate blower motor bearings with a recommended grease type. Perform operation when at normal operating temperature, but not running. Do not overlubricate. See Mfg.

Check air filter and replace, if necessary. Monthly

Inspect and clean evaporator coil to ensure there is no obstruction to air flow. Annually

Before the cooling season, check and clean the condensate drain. Annually

Check control system and devices for improper operation. Repair, adjust, or replace components to maintain proper operation. Twice yearly

Check wiring and connections for tightness, signs of overheating or discoloration. Tighten as necessary. Twice yearly

Check gas piping past gas stop for leaks and loose connections. Tighten or repair as necessary. Twice yearly

Check motor contactor for pitting or other signs of damage.

Before beginning of cooling season.

Check fan blades for balance and particulate buildup and fan motor for proper operation. Clean, repair, adjust, or replace as needed. Twice yearly

Check refrigerant system pressure and oil levels using manufacturer approved subcooling methods. If outside recommended levels, find and repair cause, and then adjust to achieve proper levels.


Check Integrity of panels and fasteners. Replace fasteners as needed to maintain equipment integrity. Twice yearly

Check damper for proper operation. Repair, adjust, or replace as needed. Twice yearly

Inspect air-cooled condenser surfaces. Repair or clean as needed.


Check belts for tension, wear, cracks, or glazing. Replace as needed. Twice yearly

Visually inspect internal ductwork for integrity and, if applicable, ensure insulation has not degraded. Correct as needed. Twice yearly


Split Systems, Condensing Units


Check control system and devices for improper operation. Repair, adjust, or replace components to maintain proper operation.

Before the beginning of cooling season

Check power terminals for loose connections. Tighten as necessary.


Check motor contactor for pitting or other signs of damage.


Check fan blades for balance and particulate buildup and fan motor for proper operation. Clean, repair, adjust, or replace as needed.


Check refrigerant system pressure and oil levels, using manufacturer approved subcooling methods. If outside recommended levels, find and repair cause, and then adjust to achieve proper levels.


Check integrity of panels and fasteners. Replace fasteners as needed to maintain equipment integrity.


Split Systems, Air Handlers (Trane)


Check filter and replace, if necessary. Monthly

Before the cooling season, inspect the cooling coil, drain pan, and condensate drain for cleanliness. Clean as necessary. Annually

Before the heating and cooling seasons, inspect the blower motor wheel for cleanliness. Clean as necessary. Twice yearly

Inspect electrical connections for tightness and controls for proper operation. Twice yearly

Check integrity of all panels and fasteners. Twice yearly

Lubricate field serviceable bearings. Annually

Visually inspect exposed ductwork for integrity and, if applicable, ensure insulation has not degraded. Correct as needed. Twice yearly

Check heating coil for proper operation. Repair or replace as needed.

Before beginning of cooling season


Air Handlers/Gas Fired Furnaces


Change air filter Every 60 days

Check control system and devices for improper operation. Repair, adjust, or replace components to maintain proper operation. Twice yearly

Check drain line and drain pan. Clean as necessary to maintain proper operation. Twice yearly

Check oil for dirt or evidence of biological growth. Clean as necessary. Twice yearly

Check wiring and connections for tightness, signs of overheating, or discoloration. Tighten as necessary. Twice yearly

Check blower motor for proper operation. Clean, adjust, or repair to maintain proper operation. Twice yearly

Check belts for tension, wear, cracks, or glazing. Replace as needed. Twice yearly

Check integrity of panels and fasteners. Replace fasteners as needed to maintain equipment integrity. Twice yearly

Lubricate field serviceable bearings. Twice yearly

Check combustion chamber, burner, and flue for deterioration, moisture problems, condensation, and combustion products. Clean, test, and adjust combustion process for proper operation, if applicable.


Check heat exchanger. Clean as necessary to ensure proper operation and remove scale and sediment. Check for leaks, if applicable.



5.0 ENERGY MANAGEMENT CONTROLS

Observations

The EMCS that is being used is Niagara front end software. The system was a full DDC system with dynamic graphics. The graphic displays were observed for Henderson Elementary during the summer and school was not in session. On the main page of the EMCS, it had a layout of the school. The school was split into several zones, which were classrooms and areas grouped together. The user could click on a zone and get a closer look at the area. Once zoomed in, the user could see how many units there were in the particular zone and the areas they served. The space temperatures were displayed as well. From here, by clicking on the rooms, it would then show the units information.

The EMCS showed a graphical representation of the unit as well as several setpoints and status points. The detailed page of the unit provided the user with much information. The detailed page displayed: space CO2, space humidity, supply air temperature, supply fan command, economizer command and status, actual cooling and heating setpoints, outside air temperature and low and high alarm limits. The outside air temperature was not displaying correctly on the EMCS, although, it did not critically affect the system. Through the central office computer control in maintenance building, it allowed the user to adjust several setting and if necessary, put some of the components in manual. The occupied cooling capacity range could be set from 70°-80° F but is usually in the range of 74°-78° F. The occupied heating could be set from 65°-75° F but is usually in the range of 68°-72° F. In the classrooms, the deadband could be adjusted ± 2° F and override is available to teachers for 30 minutes. The unoccupied setpoints were 85°F/55°F. The CO2 setpoint is 1100 ppm. These settings are controlled and could be adjusted by the maintenance director. There were two of lockouts based on outside air temperature. If the outside air temperature was greater than 68° F, heating would be locked out. If outside air temperature was less than 60° F, cooling would be locked out.

The ECMS also allowed for time schedules. Profiles could be set up for different parts of the building with time of day scheduling. Holiday schedules could be set up also. One of the drawbacks to the system is, if the lights are on the ECMS system, they are integrated with the HVAC equipment. If the HVAC units were on, then the lights had to be on as well. Other Comments/Estimates

The settings for HVAC are suitable for energy efficiency.

It was reported that the units have no specific humidity control. One option that should make some difference is to change the mechanical cooling lockout setting from 60°F to 55°F.

The Maintenance Director/Energy Manager is very aware of the system and how to operate.

Control the economizer and outside air schedule on time-of-day or unoccupied vs. occupied mode as well as current CO2 demand control. Set outside air damper to fully closed in unoccupied times.

Estimate savings of above sequence modification. Kwhr/yr = 7425 $/yr. = $1000

Estimated cost: $120


6.0 REPLACMENT PROJECTS

The following are retrofit opportunities evaluated for Henderson Elementary School. Replace Gym Lighting

The existing gym has 20 metal halide (250 watts each) light fixtures. There is some daylighting in the gym. Recommend replacing metal halide fixtures with T-5 HO energy efficient fluorescent fixtures. Incorporate occupancy sensors to control lighting.

Estimated Cost = $6,000 Estimated Kwhr savings = 4902/yr. Estimated $/saved = $603/yr. Power Factor Correction

During the on-site meeting a question was asked about power-factor. Elementary schools typically do not have low enough power factor to warrant installing power factor correction. The specific power factor for each 12 months is not currently available for Henderson Elementary.

Another question about power factor was concerning the effect of computers on power factor. The following discussion provides information on this topic.

Power supplies for personal computers typically have power factors in the range of 0.70. Some manufacturers have begun using power factor corrected power supplies, with power factors approaching 1.00.

Empirical evidence suggest that desktop computers can account for up to about 10% of a schools total electric load. Where notebook computers are utilized, their portion of the load is less. If only charging of notebook computers takes place, then power usage is minor.

Where desktop computers with power factor of 0.70 and totaling 10% of building load, overall power factor may be affected slightly. A reduction in power factor of about 2-3% or so might be reasonably expected. If notebook computers, with lower power consumption than desktops, are used, the impact will be less significant. If note book computers are only charged, the effect would be negligible.

High Schools typically provide more opportunity for dollar savings by power factor correction. The specific power factor data for the two high schools is not currently available. These campuses are recommended as the first to evaluate. Occupancy Sensors – Lighting Control

Occupancy sensors turn lights off in spaces after a preset time when no people are detected. They can be utilized in classrooms, halls, meeting rooms, libraries, storage areas, coaches offices, dressing rooms, etc. A variety of studies indicate that lighting energy savings of 20% or more may be used from utilizing occupancy sensors.

Henderson Elementary lighting control was reported to be tied into the central EMCS for HVAC. During the visit several rooms were observed unoccupied with lights on. Henderson Elementary – Fluorescent Lighting

Fluorescent lighting in the school already has electronic ballasts. The district is in process of replacing existing 32 watt lamps with 25-28 watt lamps.


7.0 ON-SITE TRAINING

The SECO approved Technical Assistance included informal on-site training for building operators staff and maintenance staff in conjunction with delivery of the Technical Assistance report to Forney ISD. Training Outline/Plan

Discussion Forney ISD energy performance review

Review each section of report and include strategies to implement

Discuss district-wide HVAC Master Plan and benefits

Date post:	27-Aug-2020
Category:	Documents
Upload:	others
View:	0 times
Download:	0 times

July 2010 SUMMARY ENERGY EFFICIENT HENDERSON … · AUSTIN, TEXAS 78774 PHONE: (512) 936-9283...

Documents