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Understanding HVAC Part Two
Patrick Finnemore Facilities Director
Kenosha United School District
John Heck Project Manager
CESA10
Chippewa Falls, W
Understanding HVAC
Maintenance Strategies
Computerized Maintenance Management Systems
Case Study of HVAC Retrofit
Behavioral Based Energy Management
Questions and Answers
Part Two
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Maintenance Strategies
The History of Maintenance Evolution Fitting the Right Strategy In a Perfect World…..
Total Cost of Operation
ASHRAE – American Society for Heating, Refrigeration & Air Conditioning Engineers
Operation 50%
Construction 11%
Financing 14%
Alterations 25%
Operations Budgets
Capital Budgets
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Students in well-maintained facilities score 11% higher on standardized tests.
A well-structured maintenance strategy will allow district administration to make informed decisions concerning:
Facility maintenance programs
Productivity processes
Resource allocation
Decisions will be made about these with or without the proper tools.
Maintenance – Ensuring that physical assets continue to do what their users want them to do.
Reliability-centered Maintenance – A process used to determine what must be done to ensure that any physical asset continues to do what its users want it to do in its present operating context.
Maintenance Strategies n Reactive
n Preventive
n Predictive
n Condition-Based, Reliability-Based, Knowledge-Based, Buzz-Word-of-the-Month-Based
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The Evolution of Maintenance Strategies
1900’s
Reactive
1960’s
Preventive
Preventive Weakness
“The best time to determine how well a piece of equipment is running is when it is running”. “Prevention tasks are almost always performed when the equipment is down and most detection tasks are performed when the equipment is running”.
J. Richard Word, CMRP, 2004
1900’s
Reactive
1960’s
Preventive
1980’s
Predictive
The Evolution of Maintenance Strategies
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WAVEFORM DISPLAY 02-Aug-00 14:49:35 RMS = 1.89 PK(+) = 10.78 PK(-) = 13.55 CRESTF= 7.16
0 40 80 120 160
-15-12
-9-6-30369
Time in mSecs
Acc
eler
atio
n in
G-s
001 - Exhaust Fan EF-3EF-3 -M2H Motor Inboard Horizontal
ROUTE SPECTRUM 02-Aug-00 14:49:35 OVRALL= .1321 V-DG PK = .1318 LOAD = 100.0 RPM = 1785. RPS = 29.74
0 30 60 90 120 150
0
0.01
0.02
0.03
0.04
0.05
Frequency in kCPM
PK V
eloc
ity in
In/S
ec
001 - Air Handling Unit 5AHU-5 -M1A Motor Outboard Axial
Time in mSecs
Acc
eler
atio
n in
G-s
0 40 80 120 160
PlotSpan
-15
15
15-Jul-04 12:18
14-May-04 10:36
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Spectroscopic Analysis Date 9/22/2004 8/19/2004 7/22/2004 5/13/2004
Lab No. 206227 204170 202511 198382
Iron 267 454 1122 2979
Chrome 3 6 13 33
Nickel 8 41 108 108
Copper 25 118 216 274
Lead 9 4 4 4
Tin 0 0 1 1
Silver 0 0 0 0
Aluminum 8 9 57 102
Silicon 55 216 607 1668
Sodium 7 0 7 18
Boron 24 3 12 17
Molybdenum 1 1 1 2
Magnesium 5 4 15 18
Calcium 268 125 237 224
Barium 0 0 0 1
Phosphorous 246 420 380 475
Zinc 34 428 212 135
1900’s
Reactive
1960’s
Preventive
1980’s
Predictive
1990’s
CBM
The Evolution of Maintenance Strategies
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Criticality Matrix Area Served Risk Mechanical
HistoryClassroom 10 School's Out 10 High 10IT 10 Injury 7 Above Average 7Communication 5 Safety 5 Average 5Environ. Support 3 Comfort 3 Below Average 3Equip. Support 2 Minimal Risk 2 None/Low 1
% Asset Life Aged O&M Costs Redundancy
More than 100% 10 Level 4 10 None 1095-100% 7 Level 3 7 Seasonal 785-95% 5 Level 2 5 Shared 550-85% 3 Level 1 3 1 Spare 20-50% 2 Generalist 1 More than 1 Spare 1
PdM/PM/Inventory 25-50PM/Inventory 15-24Inventory only 10-14
No activity 0-9
Fitting the Right Strategy
• Maintenance-preventable failures only
• Critical systems/components only
• Model should account for lost “Facility Use”
The Reliability Maintenance Model
1. Would the maintenance change produce a significant improvement in reliability and downtime?
2. What value would this add to the organization in relation to the current value of the asset?
3. What other areas might be addressed before the maintenance activity is improved?
4. What should be measured to monitor asset value and maintenance effectiveness as you plan?
The Reliability Maintenance Model
Fitting the Right Strategy
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Computerized Maintenance Management Systems
COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEMS
NOTE: WASBO offers a separate session just on this topic if you are interested in greater detail.
We will cover the basics: ü WORK ORDERS
§ Process § Backlog/Closeout Reports
ü PM’S
WORK ORDERS
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► A means to communicate maintenance needs
► Allows for tracking
● Current status
● Backlogs
− By trade
− By school
− Etc.
► Maintenance history on equipment
WORK ORDERS
EXAMPLE REPORTING – BACKLOGS No WOID Descriptions Request Date Priority Requester AssignedTo Location Area Type Area Number Craft51 9659 Please have the electricians
replace the light fixtures in the men's shower rooms. While working on a ballast this morning, we noticed that the fixtures did not seal correctly(due to age), leaving a exposed space for water to enter. Thanks.
9/17/2014 Medium Dominic Giannini
Curtiss, Rob Bradford Gym Men's team shower Room
Electrical
52 9662 Conduit pulled out of side of building, insulated wires are partially exposed. Can an electrician look at this please. This is located on NE corner of building just east of door #4.
9/17/2014 Medium Brian Vergenz
Eisenhauer, Steve
Lance Exterior Electrical
53 9666 Rebuild 4' light fixture. 9/17/2014 Medium Ken Paul Randle, Jon Bullen Classroom 112A Electrical
54 9667 Rebuild 4' light fixture. 9/17/2014 Medium Ken Paul Randle, Jon Bullen Cafeteria 149 Electrical
55 9668 Rebuild 4' light fixture. 9/17/2014 Medium Ken Paul Randle, Jon Bullen Classroom 217 Electrical
56 9669 Rebuild 4' light fixture. 9/17/2014 Medium Ken Paul Randle, Jon Bullen Classroom 117 Electrical
57 9674 can someone hook up the kiln machine ? account#145-2410-0002311. thanks
9/17/2014 Medium Thomas Deleon
Eisenhauer, Steve
Forest Park Custodial door#10 Electrical
58 9678 Rob, I would like to use the circuit tracer. When ever you can get it here is good. I do not know if two weeks will be enough time. I will do as many as I can.
9/18/2014 Medium Curt Vergenz
Curtiss, Rob Harvey Custodial 100 Electrical
59 9683 Please install an electrical outlet in old shower for sump pump. Any questions see Jim or Joe. Thanks!
9/18/2014 Medium Joe Matteucci
Eisenhauer, Steve
Washington Custodial Room 2 Electrical
60 9689 I need some electricity traced back to its source...thanks
9/18/2014 Medium Bill Harris Curtiss, Rob Grewenow Electrical
EXAMPLE REPORTING – W.O. CLOSEOUT No. WOID DescriptionPriority Status Craft Assigned ToLocation Area Desc Days Aged Request DateActual Completion DateLabour HoursTotal Costs Action TakenRequester NamePurpose947 2474 A/c not
working properly. Found 3 way valve leaking. Replaced valve and adjusted. On trolls.
Medium Closed Work Orders
Heating/Ventilation /Air Conditioning
Sorenson, Dave
Wilson Lounge 14 8/20/2013 9/3/2013 4 $354.99 Adjusted pressure switch. Cleaned condenser. Replaced thermostat. Ordered air switching valve.
Dave Sorenson
948 2960 Please checkout the circulating pumps. They have been
Medium Closed Work Orders
Heating/Ventilation /Air Conditioning
Dunst, Ron Wilson Boiler Room
39 9/9/2013 10/18/2013 5 $147.50 Low cut off float was bent and was causing it to stick.
Mark Brown General Maintenance
949 4795 Please advise on how to maintain chemical levels in boiler #1. I
Medium Closed Work Orders
Heating/Ventilation /Air Conditioning
Dunst, Ron Wilson Boiler Room
93 12/9/2013 3/12/2014 1 $29.50 This is no longer a problem
Mark Brown General Maintenance
950 3967 Please checkout boiler #2,When running #1 over night or over the weekend, #2 continues to overfill.
Medium Closed Work Orders
Heating/Ventilation /Air Conditioning
Dunst, Ron Wilson Boiler Room
28 10/28/2013 11/25/2013 6 $302.00 I found numerous problems here ,the first was that it would not go down to fow fire position to start so I found a few
Mark Brown General Maintenance
951 5138 Yearly - PM Schedule created on 11/19/2013 - Refer to PM schedule details.
Medium Closed Work Orders
Heating/Ventilation /Air Conditioning
Brown, Mark
Wilson 3 12/31/2013 1/3/2014 1 $21.72 Kevin Christoun
Preventive Maintenance
952 8004 Yearly - Boilers - Refer to PM schedule details.
Medium Closed Work Orders
Heating/Ventilation /Air Conditioning
Brown, Mark
Wilson 9 6/14/2014 6/23/2014 3 $65.16 Kevin Christoun
Preventive Maintenance
avg. time to complete 2013-2014
20.08
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PREVENTATIVE MAINTENANCE
PREVENTATIVE MAINTENANCE
Case Study of HVAC Retrofit
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HVAC RETROFIT CASE STUDY
PK-5 Elementary School
Original Construction Date: 1953
Original Building Size: 47,680 SF
Building Renovation: 2006 & 2007
New Building Size: 65,778 SF
PRE-RETROFIT HVAC SYSTEM
Steam heat
Unit ventilators for classrooms
No air conditioning except window units in main office & computer lab
Air handling unit for common areas – Gymnasium, Cafeteria & Surrounding Spaces
Pneumatic controls with front end DDC (mid to late 1990’s)
2006/2007 BUILDING RELATED MODIFICATIONS
18,000 SF Addition
New cafeteria, main office & 8 classrooms
Renovate remainder of school
Infrastructure upgrades, including new HVAC system
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NEW HVAC SYSTEM OPTIONS CONSIDERED
1. Expansion of steam heating plant & add unit ventilators to new classrooms with no air conditioning
2. Convert building to hot water heating with modular boilers & new unit ventilators with no air conditioning
3. Same as #2 but add air cooled chiller & cooling coils in new unit ventilators
4. Convert building to hot water heat, add air cooled chiller, and install modular air handling units with VAV boxes & ducted air distribution system
NEW HVAC SYSTEM OPTION SELECTED
Option #3
New modular hot water boiler system
Replace unit ventilators with new unit ventilators
Retrofit & refurbish existing air handling unit
New air cooled chiller
New DDC control system
CONSIDERATIONS DURING DESIGN DECISION
1. Budget tolerance of School Board
2. Amount of addition vs. size of existing building
3. Available floor to ceiling height
4. Building footprint – single-story with a sprawling footprint
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NEW SYSTEM
ENERGY CONSUMPTION COMPARISON
ENERGY CONSUMPTION COMPARISON
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Estimated Prairie Lane Energy Savings Based on FY05 Comparison: Onpk kWh Offpk kWh Onpk kW Gas (Thrm) Cost
Estimated Annual Use with No Energy Improvements
FY05est: 160,399 118,772 2,321 40,533 $79,501
Extrapolated Annual Use With Energy
Improvements FY08est: 168,646 138,310 2,365 26,230 $65,464
Savings: -8,247 -19,538 -44 14,303 $14,037 FY05est is adjusted for weather, added square footage, air conditioning. FY08est is extrapolated from a partial year of data to a full year and adjusted for summer air conditioning use.
ENERGY CONSUMPTION COMPARISON
Behavioral Based Energy Management
Equipment
Ope
ratio
ns Behavior
How do you manage energy?
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Behavior Change
1. One
2. Two
3. Three
4. Four
5. Five
How many coal cars does it take to produce the equivalent of one coal car of useable energy?
3
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Energy content of
coal: 100 units
Energy used to power a light:
36 units
Reprinted with permission by the Na3onal Academy of Sciences, Courtesy of the Na3onal Academies Press, Washington, D.C.
Savings with Behavior Changes
Implementing Change
n Very difficult
n Incentivizing
n Long lasting
“Anyone can turn off a light and save energy – the habit of turning off lights saves money.”
Melissa Rickert, CEM, CESA 10
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Understanding Energy Concepts for staff to understand:
n kilowatt hours (kWh)
n kW or Demand
n Therms
n Efficiencies of Equipment
n Return on Investment or Pay Back
00:00
01:00
02:00
03:00
04:00
05:00
06:00
07:00
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
21:00
22:00
23:00
kW (a
verage pow
er over 1
5-‐minute interval)
Time (15-‐minute intervals)
Example Single day profile
How do you identify behavior-related energy saving measures?
• Energy Manager – Surveys – Observa3ons – Energy Teams
• Vendors • On your own – trainings/seminars
Identifying Savings
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Benefits of Behavior-Based Energy Management
Facilitate a culture change so that energy conservation is not an ‘add-on’ but a part of the school culture (CULTURE CHANGE) Engage staff in way where their voice is heard and energy expectations are clearly communicated with rationale (COMMUNICATION) Efficient equipment will only get you so far… the people operating the equipment need to understand why and how or they will slip into old, inefficient routines (EDUCATION)
Questions and Answers
Thank You
