10 Best Building Retrofits

Manufacturers increasingly are seeking energy and operational efficiencies through building retrofits and retrocommissioning.

The most frequently asked question is, How do I get started down the path of using resources more efficiently in our facility? The second is, What can I implement now?

Ultimately, the answers depend on numerous factors. Several overarching strategies and specific tactics can get you headed in the right direction.

How Do We Start Down the Path?

Conduct a Holistic Site Assessment. Be sure that the assessment considers all aspects, including the facility, processes, and people.

During a site assessment, information is gathered about the performance of a building and its systems. The goal is to identify opportunities for improving energy efficiency and reducing cost. This information lays the groundwork for potential investments in energy and operational efficiency measures.

Energy site assessments should go beyond reviewing only the basics, such as lighting and programmable thermostats. It should also include a review of the whole HVAC system, process systems, utilities, water, and building envelopes.

Identify Retrocommissioning Opportunities. Retrocommissioning is a systematic process for identifying less-than-optimal performance in a facility’s existing equipment and control systems and making necessary repairs or enhancements to save energy and cost.

Through a functional performance assessment of mechanical and electrical systems, HVAC, and control systems, you can quickly determine where energy dollars are being wasted and where you can maximize use of electricity, gas, water, steam, and compressed air.

Implement Continuous Commissioning. Manufacturers that seek to extend the value of any retrocommissioning initiative may wish to pursue continuous commissioning of facilities.

With technology such as data analytics and fault detection diagnostics and follow-up procedures such as regular site assessments, optimal performance can be ongoing. Continuous commissioning automates the process of analyzing data in real time to ensure that systems and equipment continue to operate within expected performance parameters.

Knowing there is a problem is one issue, but you need to close the loop and ensure that actions were taken to correct the problem. By integrating the analytics element of continuous commissioning with work order management systems, you can track actions that will result in bottom-line cost savings.

Analyze Data. One of the greatest opportunities for energy savings lies within the ability to interpret and make sense of the data collected, managed, or otherwise created by building systems. Next-generation diagnostics and analytics transform data into information that can be used to make decisions that lead to overall improved performance and reduced costs. Armed with this depth of information, you can take action to reduce your costs of operation.

Measure and Verify. This is essential to knowing how your facility consumes energy and how effectively you’re managing it. You need real-time feedback on the effects of energy conservation tactics that you implement (see Figure 1). That
way, you can guide their management for optimum facility performance.

Monthly reports and dashboards of key building operating data, such as electricity, gas, water, steam, compressed air, and temperature, can be invaluable. This data, measured individually or collectively, offers a valuable tool for monitoring and managing building efficiency. Submetering various areas of the facility or production processes can yield information that can be correlated to production output. Common submetering areas are workcells, machines, and departments.

For example, Web-based executive overviews of the most critical building information can be displayed in a dashboard so you can quickly and easily view key performance data. Looking at energy usage patterns and identifying exceptions can lead to better maintenance, asset usage, and production scheduling decisions.

What Can We Implement Right Now?

Performance data can be posted in visible areas for real-time tracking.

The second most frequently asked question by manufacturers seeking efficiency is, What can I do now?

Often it takes time for manufacturers to take an in-depth look at inefficiencies and, ultimately, to adopt a holistic approach to energy savings. The following 10 tips can help save money in the short term and strengthen support for a longer-term view of efficiency initiatives that will pay off for years to come.

1. Install occupancy control sensors. These are fairly inexpensive and can save energy by turning off lights in unoccupied areas. Also, using occupancy sensors for the variable-air-volume boxes in meeting rooms can reduce the total air required by the system. This allows variable-frequency drives (VFD) to ramp down and reduce the volume of outdoor air that needs to be conditioned.

2. Implement demand control ventilation. This uses CO2 sensors to minimize the outdoor air entering a facility. It saves energy by reducing the amount of air to heat and cool. Turn off unnecessary exhaust fans whenever you can. These fans pull conditioned air from the building.

3. Properly maintain equipment. Equipment in good working order runs efficiently and reduces downtime.

4. Eliminate temperature-sensing interference. Look for things that might interfere with a correct temperature sensor or thermostat reading. Is a hot copy machine under the thermostat? Is a light shining on it? Is the thermostat located next to the loading dock door? All of these things will cause an HVAC unit to run more than it should. Move the sensors to a better location.

5. Disable HVAC set-point control. Settings should be standardized and locked out to prevent individual heating and cooling preferences. Uncomfortable temperature levels may indicate another problem, which typically is resolved during regular site assessments.

6. Employ day lighting. Use photo sensors to take advantage of day lighting. Lights will dim or turn off automatically when sufficient natural light is available.

7. Clean HVAC filters. Remove dust and pollen from HVAC filters. Dirty filters increase air resistance, make fans work harder, and reduce motor life. Consider upgrading to high-efficiency filters to save additional energy.

Figure 2
Lifecycle management identifies opportunities to reduce costs and improve operating efficiencies and productivity. This chart demonstrates the savings that each stage can generate over the life of a building.

8. Adjust boiler reset temperature schedule. Automatic adjustment for outdoor temperature changes optimizes energy use.

9. Install heat recovery system. Look at production processes that generate heat. Consider heat recovery equipment.

10. Optimize compressed-air and process cooling systems. Both are significant energy consumers in a plant and often are not optimized.

There’s No Silver Bullet

Manufacturing management responsible for operational and financial performance often seek a silver bullet to improve cash flow as it relates to building performance. In many cases, decisions are based on low initial price without consideration of the operating, maintenance, educational, and other costs incurred over the life cycle of a building or asset.

Using a life cycle approach is far more effective when retrofitting an existing facility or machinery, or when simply seeking to improve operations and maintenance (see Figure 2).

This affects not only the bottom line, but also the sustainability and environmental impact of the building. Now that manufacturers are driving sustainable business practices through the supply chain to reduce their overall environmental footprint, this can have a significant impact on top-line revenue as well.