# Presentation: 912355

## Integrated Retrofits for Federal Projects

**Dr. Lisa Gartland**

## 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**

## 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**

## 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**

## 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**

## 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.

## 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**

## 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**

## 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!**

## 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**

## 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**

## 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

##  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**

## 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**

## Hurley Building Integrated Energy Program

**Lighting improvements and new maintenance contract help pay for HVAC system changes**

## 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**

## 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**

## 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**

## 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.

## 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**

## 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**

## 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**

## 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**

## 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**