By Chris Matt
Building Operating ManagementPart 1: Poor Design Leads to Retrocommissioning
When Roger Boyington and his department took control of the Maine Medical Center Research Institute in 2000, the facility was brand new. The problem was, it did not operate the way a new facility should. Instead, it was wasting energy and driving up utility costs like a building in need of repair.
So, four years after construction crews turned over the research facility, Boyington and a team of staff and consultants decided to retrocommission it, hoping to eliminate inefficiencies while improving the bottom line. As unusual as it might be to retrocommission a four-year-old facility, Boyington had no choice considering the institute never performed as intended since the day he received the keys.
“It was ineffective commissioning, and there were some design issues in the very beginning that caused the building to operate very poorly,” says Boyington, Maine Medical Center’s director of engineering services. “Initially, we had undergone the retrocommissioning process to see how much we could tweak the building before we looked at more intensive fixes for the conditions we were experiencing inside the building.”
Boyington and his team had to identify low-cost and no-cost retrofits related to the building’s components and operations, as well as the unavoidable, more expensive upgrades. The team focused its attention on the building’s HVAC and lighting systems, and the organization has reduced energy use and lowered utility costs since completing the retrocommissioning project in fall 2004. The maintenance and engineering department’s proactive approach helped eliminate inefficiencies that only would have worsened as the building aged.
Stumbling at the Start
The research facility in Scarborough, Maine, is five miles from the primary campuses that comprise the Maine Medical Center in Portland. The medical center features two campuses in Portland totaling almost 1.5 million square feet, and the Scarborough campus has four buildings totaling 320,000 square feet. Out of all that space, it was the relatively small 62,000-square-foot research facility that was giving the engineering department its biggest headache.
“At some point, it was overwhelming,” Boyington says. “You realize you need to assemble a team of folks that could really dedicate themselves to the fixes and identifying the root causes of what was going on.”
Laboratories are energy intensive in nature, due to the need for 100 percent outside air. Typical commercial and institutional facilities operate at 25 percent outside air, Boyington says. But from Day 1, he knew the institute’s high energy demand went beyond typical requirements for laboratory energy use. Unfortunately, the maintenance and engineering department did not understand the level of inefficiency until the building was occupied. Boyington and his department were not involved in the design and construction process, so their input came only after the systems were up and running.
For example, the building was designed to function off return air, despite the laboratory’s need for 100 percent outside air. Nobody changed the capacity of the chillers, the capacity of the air handler or the size of the air intakes to account for the 50 percent of air the building was not getting back.
“It took us awhile to get our handle on it, but it was clear that a lot of the bugs in the building weren’t working themselves out,” Boyington says of the mechanical and control systems. “As the building ages, a lot of those either go away or they correct themselves. (But) the bugs seemed to be multiplying.
“There were more of them, so we undertook this retrocommissioning approach utilizing a consultant. We realized we didn’t have the expertise in house to do this.”
Part 2: Retrocommissioning: Calibrating HVAC Controls Saves Energy
Boyington’s retrocommissioning team included a design engineer, a consultant, general contractors, and maintenance and operations staff. The consultant recommended 18 measures the research facility could implement to reduce energy use and costs. The medical center incorporated 15 of those measures into the renovation project and is implementing the three remaining recommendations.
The most significant retrofit came in the form of a 30-ton, 12,000 cubic feet per minute air-handling unit installed on the rooftop above the institute’s administrative offices. The facility’s original design called for the central HVAC system to cool the laboratory spaces and the administrative offices. But because the laboratories require 100 percent outside air, the administrative offices were getting that same amount of fresh air — and consequently using too much energy — even though the air was unnecessary outside the lab environment.
Fortunately for Maine Medical Center, the team could add the rooftop unit fairly easily due to the building’s design. After adding the unit, all of the central air-handling capacity was dedicated to the laboratory side of the facility, which helped achieve the original design goals. Also, the unit above the administrative spaces, unlike the central system, can function in economizer mode. So despite installing a 30-ton air-handling unit, which typically would increase a facility’s energy use, the organization actually reduced its energy consumption, Boyington says.
While adding an air-handling unit was one of the most expensive renovations resulting from the retrocommissioning process, Boyington and his team also made significant progress toward energy efficiency with a handful of low-cost or no-cost retrofits.
For example, the first measure recommended by the consultant involved calibrating enthalpy controls for the central air-handling unit. This measure cost Maine Medical Center $1,200, but the consultant estimated it would save about $26,700 annually. This action has had the biggest payback among all the retrofits because the controls had a significant impact on improving the efficiency of the air-handling units. Ironically, a low-cost retrofit had produced the biggest results.
“It was a pleasant surprise,” Boyington says. “It definitely was not expected because nine times out of ten, you want to think that the thing that’s going to make the biggest difference is also going to cost the most. That would be the typical linear thinking.
“In the retrocommissioning world, we’ve found there are low-cost, no-cost bargains out there where certain things have been bypassed or certain things are in need of minor repairs or adjustments that allow the system to function the way it should have functioned in the beginning.”
Other measures incorporated into the project include:
• changing the operating schedule on air handlers, chillers, and boilers
• instituting a lighting survey, upgrading to high-efficiency, T8 fluorescent lamps, and specifying lighting controls
• relocating static-pressure sensors on four major exhaust fans
• isolating terminal heating equipment during non-heating season.
The retrocommissioning process began in spring 2004, and the medical center completed the retrofits associated with the project in spring 2005. Most of the renovations were related to the central plant, so despite the 24-7 nature of the laboratory, the team did not face scheduling challenges because the work took place outside of occupied areas.
“It was pretty smooth once we identified the opportunities and identified the remaining members of our team, whether it was the lighting consultant, the electrical folks or the mechanical folks that were going to help us,” Boyington says. “You identify the projects and get them on board.”
Since the completion of the project, the research institute has realized savings in energy use and costs: Energy use overall is down 10 percent. Here is a look at the annual savings related to natural gas, electricity and water:
• The research facility has cut down on natural-gas use by 2.5 million cubic feet, generating $28,600 in savings.
• The organization has reduced electricity by 250,000 kilowatts, saving $30,000.
• The building has reduced its water and sewer consumption by 1.1 million gallons, saving $7,000.
“The first thing was trying to establish a baseline (for the building), and the next thing was trying to establish the operating parameters of the systems within it,” Boyington says of the team’s approach to the project. “Then trying to make those as efficient and effective as they can be. That was the path that we used, knowing full well that it wasn’t going to be as energy efficient as some of the other buildings that we had to compare it to.”
Manager’s Role
Unlike the original design and construction process, Boyington and the operations and maintenance department spearheaded the retrocommissioning project.
“You have to be involved right from the very beginning, from the ground floor,” he says. “In the case of this building, there unfortunately was a lot of history that had gotten out ahead of us. We had a lot of catch-up to do as far as getting things going. Essentially, we took over an operating building.”
Boyington understood it was imperative his department get operating costs, energy use and environmental quality under control in a hurry. And despite the relatively young age of the building, Boyington did not waste any time getting the retrocommissioning project underway. During the project, Boyington remembered a quote he once heard related to retrocommissioning, which helped keep things in perspective throughout the process.
Says Boyington, paraphrasing the quote, “Every building gets commissioned eventually. Sometimes, those problems take 25-30 years to solve. Sometimes, it takes two weeks to solve them, but every building gets commissioned eventually. And this is one of those. As we started in the retrocommissioning process, we were finding opportunity after opportunity after opportunity of things to make better.”
Part 3: Retrofits Improve Occupant Comfort, Infection Control in ORs
While the retrocommissioning project at the Maine Medical Center Research Institute focused on energy efficiency, creating a healthy indoor environment was the primary driver for another project implemented on the organization’s main campus.
Maine Medical Center in Portland features 20 operating rooms designed and constructed in the 1980s. As more advanced medical equipment and technology made their way into the operating rooms, the maintenance and engineering department had to account for equipment-generated heat and infection control.
“In those 20-year-old (operating-room) suites, we were trying to accommodate 20 years of an exponential growth in technology,” says Roger Boyington, Maine Medical Center’s director of engineering services.
The medical center started retrocommissioning the operating rooms in fall 2006 and finished implementing the retrofits in summer 2007. While the renovations did address occupant comfort, they also improved energy efficiency.
Boyington and his team spent a great deal of time calibrating controls related to the operating rooms’ HVAC system, and they monitored pressure and airflow relationships associated with infection control.
“I’m trying to take something that was designed at 70-72 degrees in 1982 and running it down around 68 degrees and accommodating all the growth and technology,” Boyington says of the HVAC system.
The department specified variable-speed drives, air blenders, and occupancy controls for the operating rooms. The department also worked closely with the operating-room staff, infection-control personnel, safety staff at the medical center, and general contractors to achieve its goals of creating a comfortable, healthy indoor environment.
“Everyone had to work together as a team in order to do that,” Boyington says. “This was pure comfort. It had nothing to do with energy.”