HVAC Quality Maintenance A New Program for Increased Energy & Cost Savings

Transcription

1 HVAC Quality Maintenance A New Program for Increased Energy & Cost Savings History Process - Program Hosted by the California Investor Owned Utilities (IOUs) May,

2 At the live presentations this slide is used to explain evacuation procedures at the facility where the meeting is taking place.

3 Welcome & Introductions Paul Kyllo Statewide Utilities HVAC Lead Mark Cherniack Facilitator 3

4 Is HVAC Maintenance Important? Inconsistencies exist within the building industry when it comes to inspection and maintenance of HVAC systems, with some facilities following rigorous policies while a growing number are moving to a run-to-failure approach. -Robert Baker, Chair of the ASHRAE committee that wrote Standard 180 4

5 Today s Business and Economic Realities Service is like a bowl of Jello, you can t put your hands on it. When someone asks what you received you can t really tell them. - Randy Davis, U.S. Postal Service- Engineer/Architect/Administrator HVAC Contractors are faced with Operational Cost Reductions Predicting Cash Flow Inefficient Systems Customers are faced with Ongoing Cost Pressures Unpredictable Cash Flow Environmental Quality Issues

6 Delivering Value Quality Maintenance To the Contractor: Predictability & Uptime Creates opportunity to obtain ongoing recurring revenue through service agreements Differentiates contractors from their competition To the Customer: Comfort and Energy Savings Reduced total cost of ownership Thermal comfort Indoor air quality Energy savings Smaller carbon footprint Today s workshop will not just explain the programs that will help maximize contractor and customer returns, but will report on the groundbreaking process that has led us to this point. There has been historic collaboration among the utilities, the 6 HVAC, and facilities industries. Here s evidence...

7 What People Are Saying I am delighted with a program based upon ASHRAE/ACCA Standard 180, which is the professional maintenance standard as defined by our industry s governing technical body and recognized by the world s leading standards organization, ANSI. - Michael Gallagher, PE, Vice President, Western Allied Corporation Aligning California efficiency programs with nationally-recognized standards maximizes efficiencies, effectiveness, resources and just plain makes sense. - Talbot Gee, Executive VP & COO, Heating, Airconditioning & Refrigeration Distributors International This program will promote the energy behavior that needs to be demonstrated by building owners if the Long Term Energy Efficiency Strategic Plan is to be achieved. We whole-heartedly support this program. - Richard Sawhill, Executive VP, ARCA/MCA Southern California Thank you for developing a program we can support as active participants insuring its success. We look forward to its implementation and the energy efficiency it will bring to the State. - Kevin O Dorisio, Executive Director, Sheet Metal and Air Conditioning Contractors National Association 7

8 What People Are Saying We have recently reviewed SCE s Nonresidential QM Maintenance program design/implementation plan and are encouraged by what we have seen. SCE has not only relied upon Standard 180 as a cornerstone for the program's design, but has actively reached out to and taken input from contractors, associations, labor unions, and even multi-site end-users throughout the program s development. - Glenn Hourahan, Senior VP, Air Conditioning Contractors of America 8 With over 4,000 preventative maintenance agreements as the core of our business the bottom line is that it saves customer s money, prolongs equipment life and makes their home more comfortable, so we support any utility program that incorporates PMA s as a part of their energy conservation programs. - Frank Harrison, President, General Air Conditioning & Heating I am excited to hear that utilities may support a quality maintenance program based on ACCA 4 industry standards. As a licensed C 20 contractor in the state of California I have invested a lot of time and money in an effort to provide the best quality service to our customers, so this type of program only helps legitimize my goal. The fact is that heating and cooling equipment is part of a system and unless we look at the system as whole with scheduled maintenance programs there will never be any energy savings or reduced operating cost for our customers. - Tyler Miner, President, Redlands Plumbing, Heating, Air Conditioning & Home Energy Solutions

9 What People Are Saying In behalf of ASHRAE, I would like to recognize the industry outreach and collaborative approach undertaken by Southern California Edison, Pacific Gas & Electric, and PECI in development of the HVAC Quality Maintenance program. Both the program design and the enabling IT tools support the intent of ANSI/ASHRAE/ACCA Standard 180 (Inspection and Maintenance of Commercial Building HVAC Systems). Robert Baker, ASHRAE Fellow, Chairman Standard 180 Development Committee, ASHRAE 9 It is excellent that SCE is proceeding with a maintenance program based upon ANSI/ASHRAE Standard 180. I and our 2,000 Southern California members working in the service and repair field support it.. - Don Tanaka,Director of HVACR, Service and Repair, Southern California Pipe Trades, District Council #16 There are no shortcuts to achieving maximum energy efficiency from new or existing HVAC systems. There are, however, accepted and vetted standards as developed by a broad base of industry stakeholders such as ASHRAE/ACCA/ANSI Standard 180 and ACCA/ANSI Standard 4 that maximize system performance. RSES supports any and all efforts to align California efficiency programs to such proven industry standards. - Mark Lowry, Executive VP, RSES

10 Agenda 9:00am 9:05am 9:05am 9:20am 9:20am 9:30am 9:30am 9:40am 9:40am 10:20am 10:20am 10:40am 10:40am 11:20am 11:20am 12:45pm 12:45pm 1:00pm Safety Welcome & Introductions, Agenda Review CA Energy Efficiency & Utilities HVAC Program HVAC Quality Maintenance (QM) Programs Background Putting The Industry Standards to Work Part I Break Putting The Industry Standards to Work Part II Q&A, Feedback & Input Summary and Closing 10

11 California Energy Efficiency & Utilities HVAC Program James Tuleya, PG&E Jeremy Reefe, SDG&E 11

12 Why Energy Efficiency? Energy efficiency is California s highest-priority resource for meeting its energy needs in a clean, reliable, and low-cost manner. California Public Utilities Commission s 2006 publication, Energy Efficiency: California s Highest-Priority Resource State of California s priority order of energy sources: Customer Energy Efficiency 2. Demand Response/Time-Varying Pricing 3. Renewables 4. Distributed Generation 5. Clean gas-fired plants

13 The Big Bold Vision For HVAC Residential and small commercial HVAC will be transformed to ensure that technology, equipment, installation, and maintenance are of the highest quality to promote energy efficiency and peak load reduction in California s climate. Revitalized HVAC industry Increased energy efficiency, reduced peak demand Customers will demand quality installation and maintenance services Improved comfort, health, safety, and lower energy bills Installation and maintenance business models change from commodity to value-added Sustained profitability for the HVAC industry 13

14 CA Utilities HVAC Program: An Integrated, Comprehensive Solution Quality Maintenance ANSI/ASHRAE/ACCA Standards Upstream Equipment Promoting High Efficiency Equipment Quality Installation ASHRAE/ACCA/SMACNA Standards Customer Contractor relationship is central to all HVAC decisions Leveraging market delivery channels Equipment and systems designed and working correctly from the start Better customer education and decision making tools Western HVAC Performance Alliance (WHPA) stakeholder collaboration execution of CA HVAC Action Plan 14

15 Western HVAC Performance Alliance: Broad & Growing Stakeholder Collaboration Formed during 2009 with 24 charter member organizations 40% growth in 2011 bringing membership to 70 members in all but one of 19 membership categories Certifying Body Codes & Standards Official Contractor Nonres Contractor Res Contractor Association Controls Mfg or Distributor Distributor Distributor Association Educator/Trainer Government (CPUC, CEC) HVAC Manufacturer HVAC Manufacturer Association Investor Owned Utilities (IOUs) Organized Labor Other Stakeholder Owner/Facility/Prop Mgr Owner/Facility/Prop Mgr Association Publicly Owned Utility 3 rd Party Quality Assurance 15

16 HVAC QM Programs Background Mel Johnson, SCE 16

17 Looking Back on Previous California Utility HVAC Programs Delivered energy savings while focusing on a few tuneup measures. One-size-fits-all approach. Commercial CONDENSER COIL CLEANING Clean finned surfaces Residential 17 REFRIGERANT CHARGE ADJUSTMENT Check refrigerant level Add or remove charge

18 REFRIGERATION CONTROL PANEL Sequence test all controls Calibrate and clean controllers and safety controls Check setpoint of controls and limits ELECTRICAL DISCONNECT Inspect contacts loose connections Check for proper operation FILTER SECTION Replace media as required FRESH AIR, RETURN, AND EXHAUST AIR DAMPERS (Commercial only) Check for unrestricted and proper operation and close-off Lubricate bearings as required Looking Forward ANSI Standards-Based. Comprehensive and Sequenced. Opportunities maximized. REFRIGERANT AND REFRIGERATION COMPRESSOR Check crankcase heater operations, refrigerant and oil leaks, refrigerant charge and oil level and condition Perform acid test Observe bearing and operating surface temps Measure vibration COOLING COIL Inspect and clean as required Check condition of finned surfaces and straighten if bent Check for corrosion and leaks CONDENSER FAN/MOTOR Perform vibration test Lubricate bearings Examine motor mount resiliency Check motor insulation resistance CONDENSERCOIL Clean finned surfaces BURNER SECTION Perform combustion and draft tests Inspect and clean nozzles Inspect, clean and lube burner fan (gun type burners) Test safety controls RETURN AIR FAN/MOTOR & SUPPLY FAN/MOTOR Perform vibration test Lubricate more bearings Check motor insulation resistance Examine motor mount resiliency. Lubricate bearings and check for end play, excessive bearing temp and wear Check blower and clean dirt accumulation Check condition of drive couplings and belts Check for alignment, balance, security to shaft Check rotation 18

19 Collaborating to Transform the HVAC Industry WHPA Stakeholder Partnership Industry Leadership Standard 180, Standard 4 Utilities HVAC programs Enabling Environment for QM Government Utility Regulation 19

20 Residential QM & Commercial QM Plan In partnership with HVAC industry, deploy two comprehensive operations & maintenance programs that improve system performance, capture savings, and provide a high ROI to the end-user customers Key Activities Quantify energy savings benefits of quality and premium maintenance services in residential and commercial Evaluate feasibility of measures and upgrades that improve system performance Demonstrate the value to consumers of A) properly maintained systems (per industry standards) and of B) new, but proven premium maintenance practice Quality maintenance becomes the industry and market norm Demonstrate the value to contractors of a sustainable business model based on quality and premium maintenance 20

21 New HVAC QM Programs: Putting The Industry Standards to Work Part I Mel Johnson, SCE Bob Baker, FASHRAE, OPMP Wes Davis, ACCA 21

22 Building the Foundation for HVAC Efficiency in Existing Buildings Industry standards are the basis for HVAC market transformation 22

23 Building the Foundation for HVAC Efficiency in Existing Buildings The standards are in early stages of adoption, but are not new! 23

24 ASHRAE/ACCA/ANSI S-180 Title of Standard Standard Practice for Inspection and Maintenance of Commercial Building HVAC Systems 24

25 What is ASHRAE? International Academic/Professional Society Curator of HVAC science & practices Founded 1894 ~55,000 members worldwide ~220 Published Standards and Guidelines Extensive Technical Library 25

26 Std Why Developed? Research reveals majority of what is called maintenance is reactive and more akin to Run to Failure. Not only is this the most expensive way to manage a building, it leads to a bunch of added risks Energy waste Occupant discomfort Health effects 26

27 Standard 180 Purpose The purpose of this standard is to establish minimum HVAC inspection and maintenance requirements that preserve a system s ability to achieve acceptable thermal comfort, energy efficiency, and indoor air quality in commercial buildings. 27

28 Before the Standard - A lot of research Presentations to committee Technical forums and seminars Interface with other development Federal Energy Management Program EPA Hong Kong BEAM NASA 28

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30 Maintenance Approaches (US DOE) Excess costs over projected normal life cycle cost Reactive - $18/hp/year more than projected Preventative - $13/hp/year more than projected Predictive - $9/hp/year more than projected RCM* (Predictive-Preventative) - $6/hp/year more than projected *Reliability Centered Maintenance 30

31 Objective for 180 The objective established for 180 was to identify conditions that would anticipate and act to forestall failure (predictive/preventative) Realize maintenance cost ~$6-9/hp/year* more than projected life cycle cost *Calculated as excess costs over projected normal life cycle cost. 31

32 Content of the Standard Definitions Dialogue with the owner Philosophy of the operation Understanding (inventory) Performance Appendix A Failure Points Appendix B Implementation (inside/outside) Timing (now or at failure) Task listings Adjustment of inspection frequencies Documentation 32

33 SPC 180 Committee 24 Voting Manufacturers Users Suppliers General Interest 23 Non-voting ~50 Consultants 5 Subcommittees Subcommittees: Air Cleaning Air Movement Controls; Heat Generation Heat Distribution Refrigeration 33

34 Acceptance of the Standard ANSI LEED EB (Existing Buildings) ICC 2009 International Mechanical Code IAMPO 2009 Uniform Mechanical Code Various International China Hong Kong Singapore Thailand Brazil 34

35 ACCA 4 QM 2007 Purpose: Establish minimum inspection requirements in the maintenance of HVAC equipment found in one-family and twofamily dwellings of three stories or less three stories or less 35

36 Scope: ACCA 4 QM 2007 (Performed) by appropriately licensed contractors Checklist tasks of inspection items and recommended corrective Presumes that the HVAC system was designed, installed, and tested This standard shall not be used to circumvent safety, health, environmental, or the equipment manufacturer s requirements. This standard excludes steam distribution heating systems. 36

37 ACCA 4 QM 2007 Development: HVAC Contractors OEM Utilities Other Associations Specialists Supporting Contributors 37

38 ACCA 4 QM 2007 Maintenance Contractor s Responsibilities: Inspect Inform Homeowner s Responsibilities: Maintain the equipment Use professionals 38

39 ACCA 4 QM 2007 Overview Homeowner interview Inventory Equipment checklists Code requirements Performance objectives Maintenance Inspection tasks Recommended corrective actions 39

40 Inspection Task Shall inspect for particulate accumulation on filters. Shall inspect air filter housing integrity and air seal. Shall inspect grilles, registers and diffusers for dirt accumulation. Shall inspect all accessible ductwork for areas of moisture accumulation or biological growth. Shall inspect integrity of all accessible ductwork insulation. Shall inspect the integrity of all accessible ductwork including: duct strapping, hangers, sections, joints, and seams. 40 ACCA 4 QM 2007 Checklist 7.1 Air Distribution System * Recommended Corrective Actions Clean or replace filters if accumulation results in PD higher than design or if airflow is outside of established operating limits. Correct as needed. Clean as needed. Install access doors as needed. Clean or replace as needed. Observe for proper alterations, rips, tears, or improper duct adhesives. Repair, seal, replace as necessary. Install access doors as needed. Note improper alterations, straps, air leaks, and improper duct adhesives. Repair, seal, replace as necessary.

41 ACCA 4 QM 2007 Documentation: Inventory Checklists Code violations Performance objectives External Conditions (OBTW ) Inaccessible items Recommended corrective actions 41

42 Break Starting 42

43 New HVAC QM Programs: Putting The Industry Standards to Work Part II Mel Johnson, SCE Marshall Hunt, PG&E 43

44 Collaboration to Operationalize Standards Broad cross section of contributors and participants Feasibility Team 1 WHPA Nonresidential & Residential Committee Nonres and Res Tasking Subcommittees IOUs Consultants Customers Contractors Program Design Team 2 IOUs ASHRAE ACCA Consultants Additional Customers Additional Contractors Upper Managers Service Managers Sales Managers Technicians IHACI ARCA/MCA UA SMACNA SMWIA Program Review 3 1 Program feasibility based on ANSI Standards was the recommendation of WHPA subcommittee, which was further refined with individual contractors and customers through an in depth process to operationalize the standards. 2 Program design team consisted of a series of focus groups, workshops and working sessions conducted over 10 months and included 4 contractors (including service leads, technicians and operations staff) 13 customers (including facility and energy managers), and 3 energy efficiency consultants. 3 A series of information sessions were held with contractor organizations and included over 40 association executives, union officials, contractor members and training center personnel. 44

45 Focusing on Three Vital, Customer-Centric Components of Success Three interdependent customercentric components for success: Thermal Comfort» The customer is not too hot or too cold Indoor Air Quality» Smells, allergies and air particles are minimized Energy Efficiency» Lower monthly energy bills 45

46 Standard 180-based 3-year QM Service Agreements Introducing the New Commercial QM Program Treatments are presented in a composite package Initially targets commercial rooftop units (RTUs) 46 Includes a comprehensive (yet fairly standard) suite of program elements to address market barriers (marketing, IT tools, training, incentives, etc.).

47 Introducing the New Residential QM Program Standard 4-based QM Service Agreements Treatments are presented in a composite package Initially targets single-family detached and duplex homes Includes a comprehensive suite of program elements to address market barriers (marketing, IT tools, training, incentives, etc.). 47

48 Foundation for A Quality Focused HVAC Sector Industry transformation Data & Information Building, RTU, QC Long term relationships Contractor-Customer Innovation Premium measures Retrofits Standard 180-based and Standard 4-based Service Agreements set the stage for future HVAC upgrades 48

49 Commercial QM & Residential QM Service agreement. Fix deferred maintenance. Maintain equipment. Step 1: Service Agreement Define QM Policies/ Customer Interests Customer concerns Performance objectives Condition indicators Record Inventory of Customer s Equipment Step 2: Baseline Assess Equipment Perform Baseline Analysis Identify Required Repairs and Communicate with Customer Step 3: Ongoing Maintenance Perform Maintenance Document HVAC System Condition Indicators Provide Customer Before/After Benefits Reports Improves thermal comfort, indoor air quality and energy efficiency 49

50 Overcoming Market Barriers Customer HVAC operating costs are largely invisible Economic pressure has lead to a short-term focus ( run to fail ) Lack trust of contractor Difficult to compare contractors offers and quality of work Benefits of QM not yet quantified Demand-side Industry Lack of knowledge and tools to comply with Standards 180, 4 Standards 180, 4 viewed as only task check-lists Some tasks require additional detail to operationalize Lack of industry consensus on protocols for RCA and instrumentation Unclear career path for technicians Benefits of QM not yet quantified Supply-side 50

51 Commercial QM Customer View 3-year QM Service Agreement Incentive is based on incremental cost of Standard 180-based QM over typical service Service Agreement is transferable to other Program-qualified contractors Benefits: Engages customers in long-term relationship with contractors Provides sufficient time for QM benefits to be demonstrated Installments provide leverage to discourage deferred maintenance Transferability protects the Customer and Program Customer Incentives 3-year QM Service Agreement 20% upon signing 25% at the end of year one 35% at the end of year two 20% at the end of year three All units must be maintained to receive the full incentive amount Customer Incentives 51

52 Commercial QM Contractor View One-time service to normalize equipment in a state of deferred maintenance Incentive is based on pre-qualified baseline condition Benefits: Protects the Contractor: ensures subsequent maintenance conducted is effective Creates fresh start and an opportunity to discuss the hidden costs of deferred maintenance Contractor Incentives Task & Incentives 1-5 Tons 6-25 Tons +25 Tons Coil Cleaning $110 $130 $150 Adjust Airflow $25 $35 $45 Refrigerant System Test $25 $35 $45 Refrigerant System Service $120 $200 $260 Economizer Functional Test $25 $35 $45 Integrate economizer wiring $165 $175 $185 Replace damper motor $460 $510 $575 Replace controller/sensor $320 $370 $415 Renovate linkage & other components $180 $245 $310 Decommission Economizer $100 $130 $170 Replace T-Stat $200 $200 $200 Adjust T-Stat Schedule $25 $25 $25 52

53 Residential QM - Customer and Contractor Views 1-year QM Service Agreement Incentive is based on incremental cost of Standard 4-based QM over typical service Service Agreement is transferable to other Program-qualified contractors Benefits: Engages customers beyond one-time relationship with contractors Provides opportunity for more than one call to address both heating and cooling Transferability protects the Customer and Program One-time service to normalize equipment in a state of deferred maintenance 1-year Service Agreement recommended to be in place. Incentive is based on baseline condition Benefits: Protects the Contractor: ensures subsequent maintenance conducted is effective Creates fresh start and an opportunity to discuss the hidden costs of deferred maintenance Customer Incentive Contractor Incentive 53

54 Air Flow at OEM Minimum cfm/ton Duct Repair Residential QM Service and Condenser & Evaporator Coil Cleaning Refrigerant System Test & Service Retrofit of High Efficiency Blower and Condenser Fan Motors Retrofit Treatments 54

55 Meeting Contractor Enrollment Criteria Company financials Years in business HVAC technician requirements (trade school, 2-years experience, and/or industry certification) Local customer references Employ full-time professional with years of specific HVAC experience Job-scheduling software for visits 55 Emergency service capabilities Knowledgeable, experienced contractors and techs who will deliver for the long haul

56 Planning for Success via Contractor Training and Customer Communications Sales Background and Customer Value Proposition Program Operations Workflow Technical Field Operations Program Guiding Document Customer Leave-Behinds 56

57 QM Programs Built on Continuous Improvement Phase 1: Setting the Foundation QM based on Industry Standards Phase 2: Maximizing Energy Savings Retrofit opportunities (e.g. efficient motors, variable frequency drives, demand control ventilation etc.) Phase 3: Efficiency Upgrades Improve system performance through new technologies, such next generation economizers, fault detection and diagnostics, etc. 57

58 58 Questions Feedback Input

59 Worth A Thousand Words Look Mom: QM! 59