UNL BSM 2012 BIG...Test Case Two Air Handlers side by side Lab Building full fresh air 100,000 CFM each Original Filter 24 x 24 x 2 AH1 Filters lasted 3 months Final pressure drop

UNL BSM 2012 • June 2010 I was asked to Manage the technical set-up for our new

Preventive Maintenance Program.

• Goal was to identify minimum PM service requirements for all

buildings.

• Zone Maintenance would bring maximum efficiencies to our PM

Plan. One hour of scheduled PM reduces corrective maintenance by

two hours

• Set up zones based on geographical areas.

• Plan

• Review O&M manuals and review current operating procedures

• Current Preventive Maintenance program calendar driven.

• Use our E.M.C.S. To track, trend, & alert our maintenance service

needs. Install additional electronic tracking devices and software to

monitor critical equipment currently not monitored.

• Install new service frequencies to reflect actual needs

• Think out of the box to find a better way of doing things

Zone Maintenance

Efficiencies

O&M’s service frequency based on runtimes

Pressure Drop determine filter loading.

Total cost of ownership determines frequency of filter

change out.

Drop shipment saves time & money

Lighting Maintenance

Calibration /Verification / Retuning

Reduced number of Vans in work fleet.

Campus Facilities Square Feet

O&M’s Service Frequency not Calendar Driven

• Old School of thought

• BAD.. Calendar Driven … Car without an Odometer or a Gas Gage

• Service and lubricate equipment & change filters every 4 to 6 months

• BETTER Metered Driven Service…. On board computer

• Fan and Pump maintenance schedules reflect 2500 hours of Runtime in-between

lubrication. . Shaft size of 3” or more require lubrication service at 720 hours of

runtime.

• Motor Bearings 9000 to 18000 hours. One to two years

• EMCS System is tracking runtimes and Alarms when motors operate beyond the

Factory recommended service schedule.

• Most Fans are on Time Schedules, service frequency may differ fan to fan .

• Seasonal equipment often has redundant pumps that rotate every 200 hours. These

only need service once a year.

• Monthly checks of runtime will determine when service is needed to be scheduled.

• Change filters as needed and reduce pressure drop.

• BEST………….. Optimizing Service

• Run a algorithm to determine RPM based on VFD motor speed and adjust service

frequency. ( field verify rpm/ hertz relationship ) This will push lubrication frequency

out from 6 months to 12 / 18 months or more. Upgrade filter racks to 4” filters,

EMCS PM Program

COMPRESSOR AMPS

COMPRESSOR AMPS

Compressor Run Cycle 2 MIN ON/11MIN OFF 15%

E.M.C.S. TRACKING AMPS

EMCS

• Tracking AMPS

• Check to see if alternator is working.

• Check Run Cycle in real time.

• Monitors are added to send alarms when

equipment reaches O&M service

schedules

• Monitors are added to send alarm if amps

are 20% below normal run amps.

•FILTERS

Ring Filters

Pressure Drop determine filter loading

• Filter loading can be determined by pressure drop

across the filters.

• Getting to know how to measure filter loading is

important. When you shut the air handlers off for the

filter change the VAV boxes open in the building. Same

thing happens when they start up in the morning. After

the fans ramp up for a short time you have the

opportunity to check the pressure drop across the new

filters. Record this clean filter drop across the filter.

Where you have CFM readings record that too. Clean

Filter Pressure Drop is cataloged @ .30" ( 2000 cfm @

500 fpm ) . Your initial drop will probably be lower

because of lower flow. It will be time to replace these

filters when the pressure drop is double of the starting

rated or .60"

MAGNAHELIC GAUGE TO

MEASURE PRESSURE DROP

EMCS • Filter drop needs to be checked when fan is at

maximum air flow.

• This can be achieved by shutting off fan for twenty

minutes up in the morning or at initial starts.

• Monitors are put in place & when filter drop is twice the

initial reading we receive a maintenance alarm to check

the filters.

• At this point filters are ordered and scheduled for

replacement.

• Filters can load up to 2 ½ times initial reading with only a

slight energy increase .

ZONE 1 FILTERS

Filter check

Filter drop shipment saves time & money

• Once the next months filter quantity is known. A Zone

order is placed and the filter order is delivered directly to

the Zone.

• This drop shipment saves the time and resources of

having filters delivered to our Inventory, checking filters

in, and then checking filters out and driving them to the

building in need of filters.

• Drop shipment to our Lab Test Case saved three hours

of labor between Inventory folks and Building

Maintenance Crew.

Energy Test Case

• Light Bulb vs Air Filter Energy Savings

Air Handlers for Filter Test

Filters : Total Cost of Ownership Test Case Two Air Handlers side by side

Lab Building full fresh air 100,000 CFM each

Original Filter 24 x 24 x 2 AH1

Filters lasted 3 months Final pressure drop 1.05”

New Type Filter 24 X 24 X 2 AH2

Filters lasted 6 months Final pressure drop .60”

Total cost for one year of operation AH2 $1,754.00 2 filter replacements+ Energy

savings from .03” avg reduced pressure drop 3,000.00 $3,954.00 annual

savings

We since upgraded to 4” Filters and moved the final filters from the discharge of

the air handler to behind the pre-filters ahead of the first water coil. Additional

Cost $2.00 per filter

Both AHU’s are fitted with 4” pre-filters that are changed around once a year based

on pressure drop filters. 09/22/2011 to 09/27/2012

Before TCO After Final TCO with .5” less Pressure drop /energy savings

$5416.00 $2,144.00 = 3,262.00 + $10,000

Total Annual savings on Filters + energy savings = $13,262.00

& IAQ improved from Merv 7 to Merv 8

Filter loading 2011 TO 2012

Filter Spec

• Preferred Filter 592 X592 X 95 mm / 24 “X 24 “ X 4”

• Application: Primary filter for air conditioning systems.

• Type: High performance disposable pleated panel filter.

• Case: Rigid water resistant cardboard.

• Media: Mixture of cotton and synthetic fibre.

• EN 779:2002 efficiency: G4.

• Gravimetric efficiency: 92%.

• Clean Air Flow Pressure drop . 90 PA / .0266

• Recommended final pressure drop: 250 Pa. / .073

• Temperature: 70ºC maximum in continuous service.

• Holding frames: Front and side access housings and frames are available, Type

• FHF Front Loading Frames and FC Housings.

• Note: Filters also available with metal frames and support wire.

• ADVANTAGES

• • High mechanical strength

• • Fully supported media bonded onto a wire support grid

• • Rigid, water resistant cardboard frame

• • Large media surface

• • Unique radial pleat design

• • Bonded into case to eliminate air bypass

UV Lighting Plan

• Air handler chill water coils that show repeated mold

growth.

• Drain pans, duct work, and insulation inside an air

handler with ongoing mold.

• UV lighting is installed to sterilize and kill growth along

with cleaning the coil and lowering pressure drop.

• Local monitors are added to signal bulb replacement.

• Plan is to read monitors on EMCS system to schedule

replacement.

COIL CLEANING

Planned Lighting Maintenance

• Screw-base-type compact fluorescent lamps (CFL) offer the major

advantage of long life – up to 10,000 hours — which reduces labor

significantly. They require no external ballast and can be used in the

same sockets as incandescent lamps. These CFLs also offer

considerable energy savings. Manufacturers this year introduced

new, larger screw-base CFLs — 55, 65 and 85 W — to replace

incandescent lamps of 200, 250 and 300 W

• • Generate lighting upgrade opportunities such as reduced-output

energy saving lamps that take advantage of higher light levels to

reduce energy costs. high-cost lighting maintenance occurs in

areas that still have very-high-output or power-groove fluorescent

lighting. These lighting sysytems should be replaced with either a

high-performance T8 or T5 fluorescent system or a pulse-start metal

halide HID system. Paybacks for this investment are significantly

improved with documented maintenance labor savings, as well as

energy savings.

Steam Trap Maintenance

Calibration

Calibration

AHU Control Dampers

Verification • AHU mixed air dampers are critical in Energy

Optimization. These dampers need to be verified

for proper operation. Dampers can get stuck or

linkage can break, causing the over

compensation from the heating & cooling

systems. A simple monthly check can

pro-actively save money & comfort.

• Isolation dampers need to be checked for proper

operation too. These failures can reduce fan

output & performance.

Sustainable

• Energy Savings

– Lighting, reduced pressure drop with coil

cleaning, UV Lighting, and upgrading filters

• Reduced filter disposal by over 7500 filters

• Salt less water softeners

• Green glycol

– Sugar based…..spec available

• Ron Peters

• Contact Information

• Office: 402-472-4845

• Cell: 402-450-6391

• E-Mail: [email protected]

• Full presentation available

• Light Bulb vs Air Filter Energy Savings Study

• ASHREA 2006 Clean Coil Study