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MAINTENANCE ANDMAINTENANCE ANDCOMMISSIONING

SECTION U

IMPORTANCE OF MAINTENANCE PROGRAMS

Good maintenance saves energy costs

Major problems in maintenanceMajor problems in maintenance Lack of adequate management attention Lack of adequate maintenance training Poor reporting of problems Lack of work order systems Poor analysis of problems Poor preventive maintenance effortsPoor preventive maintenance efforts Poor control of maintenance activities

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SUCCESSFUL MAINTENANCE PROGRAMS

Require adequate funding and training

D t d f i tDo not defer maintenance

Use new Maintenance Management Systems

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MAINTENANCE MANAGEMENT SYSTEMS

MMS bring high tech to the maintenance area.

MMS provide capability for inputs from MMS provide capability for inputs from sensors such as differential pressure across filters, equipment temperatures, and vibration.

MMS provide data analysis, data summaries, generation of maintenance orders and generation of maintenance orders, and performance records on equipment.

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COSTS OF POOR MAINTENANCE

Steam leaksSt t f ilSteam trap failures

Compressed air leaksUninsulated pipesBoiler scale

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Cost of Steam Leak Chart8760 hours/year operation – pressure is gauge

4000GJ/yr

3000

2000

1000

Hole Size (mm) 1.27mm 2.54mm 6.35mm 12.7mm

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Costs of Compressed Air Leaks8760 hours/hr operation

Pressure is gauge

Hole Diameter (mm)760 kPa 690 kPa 620 kPa

9.525 226,100 208,100 190,000 6.35 100,500 92,500 86,300 3.175 25,100 23,100 21,100 1.588 6,300 5,800 5,300

Energy Loss at Pressure (kWh/yr)

, , ,0.794 1,600 1,400 1,300

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304.8mm254mm

203.2mm

GJ/yr*304.8mm

254mm

203.2mm

GJ/yr*

152.4mm

101.6mm76.2mm

50.8mm38.1mm

25.4mm

152.4mm

101.6mm76.2mm

50.8mm

12 7mm

38.1mm25.4mm

kPa 0 690 1380 2070 2760 3450 4140

12.7mm

* 8760 hours/yr operation and per 30 metres of pipe

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kPa 0 690 1380 2070 2760 3450 4140

12.7mm

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Energy Loss f from Scale Deposits

Mm 0.4mm 0.8mm 1.2mm 1.6mmThickness

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Maintenance Cost Example 1

Five bucket steam traps are stuck open in your facility. They all exhaust to the drain. If LPG

f th b il t $1 25/k d t gas for the boiler costs $1.25/kg and your steam system is 78% efficient, what is the cost of these malfunctioning steam traps per year? Each trap has a 2.5 mm orifice. The steam line pressure is 690 kPa gauge.

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SOLUTION TO MAINTENANCE EXAMPLE 1STEAM LEAK – ONE TRAP

The stuck open steam trap is like a 2.5 mm leak in a 690 kPa gauge steam mm leak in a 690 kPa gauge steam system.

From the chart, the annual heat loss for 8760 hours of operation per year is about 400 GJ/yr.

yr/070,14$78.01

kJ605,45kg1

kg25.1$

yrGJ400

yr$

=

=

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SOLUTION (CONTINUED)

In problem 1, what else should you examine?

• “They all exhaust to the drain”• They all exhaust to the drain• When you lose condensate you lose:

– Heat– Water– Chemicals– The cost of sewer disposalThe cost of sewer disposal

• Adding condensate return piping is generally quite cheap and cost effective.

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Maintenance Cost Example 2

You run a compressed air check in your facility d fi d th f ll i g l k 6 35 d and find the following leaks – one 6.35 mm and

one 3.2 mm. What is the annual cost to your facility if your system has 690 kPa gauge air and you are paying $0.10 per kWh for electricity?

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SOLUTION FOR MAINTENANCE COST

EXAMPLE 2AIR LEAK - ONE LEAK

From the table on page 37, the kWh of electrical energy needed by the electrical energy needed by the compressor to feed one 6.5 mm leak at 690 kPa gauge for 8760 hours is: 92,500 kWh/yr.

The cost of this leak is:

yr/9250$=kWh

10.0$yr

kWh500,92=

yr$

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MAINTENANCE ECMS

Develop a Preventive Operation & Maintenance Program A comprehensive O&M plan for a facility should A comprehensive O&M plan for a facility should

include PM procedures for periodically reviewing and monitoring the operating sequences, strategies and schedules to ensure that the facility operates as efficiently as possible.

Preventive maintenance should include Preventive maintenance should include activities critical to energy-efficient building operation.

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MAINTENANCE ECMS (CONT) Develop O&M procedures and forms for

tracking actual equipment performance against expected performanceexpected performance.

Forms may include: Task description, Checking method and frequency for each piece of equipment Reporting formats Procedures for addressing non-conformance issues and how to

resolve performance deficiencies

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MAINTENANCE ECMS (CONT.) Periodically review HVAC and lighting

schedules, temperature setpoints and occupant/tenant use requirements so equipment occupant/tenant use requirements so equipment runs only when needed.

Seasonally adjust control strategies. A good strategy for the cooling season is not necessarily optimal for the “swing” season or the heating season.

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MAINTENANCE HELP FROM INTERESTING

TECHNOLOGIES

Infrared PhotographyAnd

Vibration Analysis

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INFRARED PHOTOGRAPHY

Family of non-destructive testing techniquesP d i f h t ll Produces images of heat usually invisible to the human eye

Heat in some mechanical situations can be a sign of impending malfunctions

Heat in some electrical wiring can be a sign of bad connections and/or phase problemsp p

Heat anomalies in steam systems (e.g. traps)Heat loss through building envelope

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INFRARED PHOTOGRAPHY (CONT.)

Averted problems can be significant in nature (e.G. Primary transformer fires, etc.)

IR operator needs some level of expertise Attend training Contract service

One major malfunction discovered and infrared program just paid for itself

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EXAMPLE IR PHOTOS

IR PHOTO OF MALFUNCTIONING STEAM TRAP – OKLA. STATE IAC

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EXAMPLE IR PHOTOS

Example IR photo of bad electrical connection – FLIR Systems Inc.

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VIBRATION ANALYSIS

Another powerful member of the family of non-destructive testing techniques

Measures vibration signatures of machinery (usually rotating)

Two Main Diagnostic Methods1. Vibration Signatures (Snap-Shot)2. Trending (Observation Over Time)

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VIBRATION ANALYSIS CONT. Even more so than infrared photography,

training is mandatory (this is a science and t)an art)

Trending vibration levels over time can remove some of the uncertainty of problems

Technique used to spot: Bad Bearings Bad Gears Bad Gears Loose Machine Mountings

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VIBRATION ANALYSIS EXAMPLES

PROBLEM WAS LATER LOCALIZED TO THE MOTOR COUPLING. REPAIR WAS INITIATED TO

AVOID CATASTROPHIC FAILURE.

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VIBRATION ANALYSIS EXAMPLES

Water pump with suspicious (noise-floor) vibrations. Attempts to localize problem began. (Okla. State IAC)

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COMMISSIONING

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CBECS DATA

Energy Use(MJ/m2·yr)

Energy Cost($/m2·yr)

Energy Star (2000) 489 11.2

Average Buildings (1995 CBECS*) 1071 20.7

Efficient Buildings (Top 25% 1995 CBECS*) 514 12.5

* Commercial Buildings Energy Consumption Survey (US DOE)

Source: Energy Performance Pitfalls, Building Operations Management, p. 43, March 2000

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CBECS DATA

Energy Star 2000

1995 CBECS (Top25%)

1995 CBECS (Bottom25%)2000 (Top 25%) (Bottom 25%)

Economizers 70% 30% 75%VSDs 55% 20% 45%VAV 70% 35% 65%EMS 80% 25% 55%M ti S * 60% 10% 20%Motion Sensors* 60% 10% 20%* More Data Given - Not Presented Here

Source: Energy Performance Pitfalls. Building Operations Mgt, March 2000

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LACK OF COMMISSIONING EXAMPLES

Air side economizers: 50% of the time do not function properly (ASHRAE says 70%)not function properly (ASHRAE says 70%)

Chilled water pumps directly connected to CW return lines

Parallel pumps with some connected backward

Air handling units (AHU) with belts completely absent (motor still running)

One study found 650 such discrepancies

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DO IT RIGHT THE FIRST TIME

AND KEEP IT THERE

CommissioningThe process of ensuring that systems are designed The process of ensuring that systems are designed, installed, functionally tested, and capable of being operated and maintained to perform in conformity with the design intent.

Begins with planning and includes design, construction, start-up, acceptance and training, and can be applied throughout the life of the building can be applied throughout the life of the building

Refs: ASHRAE guidelines 0-2005 and 1.1-2007,others

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BENEFITS OF COMMISSIONING

Buildings and systems that function as intended Operators that know how to operate the building Op p g

effectively Greater occupant comfort More satisfied and productive occupants Reduced energy consumption and lower operational costs Reduced environmental impact Others Others . . .

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TIME LINE

The chart depicted below is one concept of how these fit together. There is nothing accurate about the actual placement of these activities on the time line; the chart is

Design Design Construction TAB Owner Acceptance Modification or Owner Acceptance

Intent Punch Out and Operation Addition and Operation

Commissioning Recommissioning

Real Time Commissioning

intended to convey thought only.

Note: Modification also includes design intent, design, construction, etc. This has been simplified.

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COMMISSIONING INVOLVES: Planning Funds Peopleeop e

Management commitment Commissioning firm Building O&M staff Teamwork — Analogy to Value Engineering

Instrumentation/Tools Tests

R lt Fi R t t Results, Fix, Retest O&M Training Documentation

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PHASES OF COMMISSIONING

Pre-Design Phase Design Phase Design Phase Proposal Phase Construction and Acceptance Phase Warranty Phase

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COMMISSIONING: GENERAL

1. Design intent is important (know what you want and express it)you want and express it).

2. Commissioning experience and training is important. Get someone with experience to help the first time(s) and obtain proper training This process can be extremely training. This process can be extremely cost effective; do it right.

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COMMISSIONING: GENERAL

3. Facility staff should be involved in the process as soon as possible. This is especially critical i h f l i i i i i i in the formal commissioning activities (systems try out and tuning).

4. Commissioning is not a “quick fix” or a “one time activity”. It is a rather dramatic change in philosophy and an on-going activity. Management will be doing some phase of Management will be doing some phase of commissioning for the entire life of the facility. Remember, it is cost effective.

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COMMISSIONING: GENERAL

5. Commissioning is not implicit in construction. Management must make it happen.

6. Commissioning almost guarantees a smooth transition.

7 Commissioning must include training 7. Commissioning must include training, systems manuals, maintenance manuals, and other documentation as needed.

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COMMISSIONING: GENERAL

8. Commissioning must include systems design for real time commissioning and parameters for when recommissioning is neededfor when recommissioning is needed.

9. Commissioning does include observation by management, but it is much more, including observation of start up, testing adjusting and balancing, and other “normal” construction steps. We must change our thinking to include these as part of the total commissioning process.

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COMMISSIONING, RECOMMISSIONING, AND REAL TIME COMMISSIONING ARECOST EFFECTIVE

See References (esp. BCBC Study, Northwest Utility Study, West Bend Mutual Insurance Company Study, and Canadian Public Schools Study).

Estimate a minimum of .5 to1% facility cost up to a maximum of 5% (4%) for a complex facility with lots of emergency and BASs; probably averages 2 to 3%emergency and BASs; probably averages 2 to 3%.

Somewhat expensive, but usually pay back within two years.

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REAL TIME COMMISSIONING

11. A Texas A&M study started Continuous Commissioning ™ on 80 campus buildings in 1995. By 1999, more than $2,000,000 was spent for metering and another $2,000,000 was spent for analysis and implementation of recommendations. Cumulative savings over the same time period were more than $10 000 000$10,000,000.

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COMMISSIONING: WHERE TO FROM

HERE?

Ch k B ildi C i i i Check Building Commissioning Association site and publications

Check ASHRAE course and Guideline 1 Check AEE course and certification

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APPENDIX

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PHASES OF COMMISSIONING

Pre-Design Phase Design Phase Design Phase Proposal Phase Construction and Acceptance Phase Warranty Phase

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PRE-DESIGN PHASE

What is the intent of the Commissioning Deficiencies in Installation Functionality of all Systemsy y Energy usage reduction Adherence to codes

Starts the process of analyzing initial dataDevelops budget guidanceWhat will be Commissioned

The entire facility with all systemsy y Only designated systems

o HVAC, lighting, emergency power, etc Provides capability for determining if retro

commissioning is beneficial

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DESIGN PHASE

Assemble Proposal Team to create, coordinate, review, and select

Prioritize and set the objectives Prioritize and set the objectives Provides opportunity to ensure all issues in design

are outlined in the RFP Provides metrics for facility performance

Develop how performance will be analyzedDevelop construction observation checklist with

timeframes Develop training plan for staff employees Start process of development of operational

manuals

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PROPOSAL PHASE

Development of the Proposal Define the Selection Process Write the Proposal Instructions

Advertise the Request For Proposal with Pre-bid Meeting

Conduct Pre-bid MeetingReceive Review and Select the RFPReceive, Review, and Select the RFP

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CONSTRUCTION AND ACCEPTANCE PHASE

Ensure checklist and timelines are being metReview designs and as-built constructionReview designs and as built constructionOversee testingPerform documentation/signoffsConduct meetings with Proposal Team and

Commissioning ProviderE C i i i P id i ti Ensure Commissioning Provider is meeting the objectives for construction/verification outlined in RFP

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WARRANTY PHASE

Following up with affected Parties to ensure any warranty issues are addressed in a timely warranty issues are addressed in a timely manner

“What’s measured and monitored – Gets Addressed and Corrected”

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COMMISSIONING DOCUMENTATION

1. Design intent and design drawings, specifications etcspecifications, etc.

2. Commissioning plan including specifications and procedures (before construction)

3. Complete documentation of all test results TAB modifications etc (as results, TAB, modifications, etc. (as built, as modified)

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COMMISSIONING DOCUMENTATION

4. Drawings and specifications brought “up to date” as needed by the changes made (“as built and modified”)built and modified ).

5. Systems manual with complete descriptions, equipment literature, drawings, etc. (complete “systems description”)

6. Maintenance manual (complete manual not just collection of equipment maintenance check list)

7. Training in operation and maintenance of all systems.

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COMMISSIONING DOCUMENTATION

8. Recommissioning plans and parameters.9 R l ti i i i t d i 9. Real time commissioning systems design

(will include many of the steps above).

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IS COMMISSIONING NECESSARY AND COSTEFFECTIVE?

1. Increasing complexity of facility systems, g p y y yspecialization of subcontractors, energy and other facility costs all say that systems tuning and retuning are necessary.

2. First cost and schedule deadline paranoia always lead to operational problems. Commissioning can help minimize these problems.

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IS COMMISSIONING NECESSARY AND COSTEFFECTIVE?

3. Traditional methods neglect input and 3. Traditional methods neglect input and feedback from people that will run the facility (operations and maintenance staff). Commissioning forces this to happen resulting in better training and smoother transition.

4. Designers and contractors rarely ti i t i th ti ( i ll participate in the entire process (especially

start up and tuning). Commissioning forces this to occur.

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IS COMMISSIONING NECESSARY AND COSTEFFECTIVE?

5. Malfunctioning automated systems are often h lf i i l Th worse than malfunctioning manual systems. The

problems usually cost more and are harder to fix. Commissioning ensures they are working at transition and that training has occurred.

6. Commissioning can cost 1 to 5% of the facility first cost but this can often be recovered in the first year of operation (very difficult to document; but think about your experiences)1.

1.Average is probably 2-3%

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IS COMMISSIONING NECESSARY AND COSTEFFECTIVE?

7. Design professionals, contractors, facility 7. Design professionals, contractors, facility operating and maintenance staff, and management all benefit from commissioning. It should be an important part of all facility construction and modification.

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END OF SECTION U

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