Tune Up Your Building Through Retro-Commissioning

Imagine a car that was designed and built, but never road tested before being put into production. The malfunctions would be plenty, and recalls would be inevitable. Customer complaints would skyrocket, and whatever car company engaged in such a lousy business plan would soon go bankrupt. Sounds crazy right? In reality, that absurd scenario would never play out, yet that is exactly what happens every time a building is built, but not properly commissioned – a building’s equivalent of road testing and fine tuning

Even buildings that were properly commissioned need an occasional tune-up to be sure all the parts are working correctly and to prevent expensive repairs. But what do you do with a building that was never properly "road tested" or commissioned at all?  A simple tune up won’t work, and unlike a car, we can’t send it back under protection of the “lemon laws!"

The answer is what is commonly referred to as “retro-commissioning”, which is a process that addresses problems that have developed throughout the building’s life, or problems that were there from the very beginning. Many issues uncovered by the retro-commissioning process are a result of the design itself, not just the way systems were installed.  Whatever the culprit, even the smallest problems have big impact on performance. The ultimate result is uncomfortable buildings, unhappy tenants, and substantial energy and maintenance costs.

Get Your Building Running at Peak Performance
Through a simple, multi-step process, retro-commissioning provides for systematically evaluating all aspects of a building and its energy-using systems. Problems can range from simple to complicated, so it is important the team performing the retro-commissioning understands how the systems are supposed to work.

According to “A Practical Guide for Commissioning Existing Buildings,” by Haasl and Terry Sharp of Oak Ridge National Laboratory, some basic items often targeted for retro-commissioning include:

• Adjustable speed drives that may not be operating appropriately.
• Time clocks that may have been circumvented or set up improperly.
• Energy management systems that were not installed or programmed or that may have degraded.
• Equipment running more than necessary or inefficiently.
• Controls that are out of calibration or are improperly sequencing.

Entegral Solutions recently completed a $9.5 million energy efficiency project at Mercedes ISD, in which we upgraded equipment and lighting, added control systems, and other conservation measures. There were many instances, however, where equipment was relatively new and in good condition, yet comfort was lacking and energy use was high. In those cases, we used retro-commissioning to bring the systems into optimal performance, both for comfort and efficiency. The general idea is to understand how the system was designed and intended to operate, and then fix the issues preventing it from operating as intended. Sometimes, we find that the design intent is the problem, and we make adjustments or modifications to the design that will produce more optimal performance. In the end, the retro-commissioning effort alone accounted for $75,000 in annual utility cost reductions, all while making the buildings much more comfortable for students and teachers.  

Energy and Non-Energy Benefits of Retro-Commissioning

For existing commercial buildings, retro-commissioning is one of the most cost-effective means of improving energy efficiency. There are several energy and non-energy benefits resulting from retro-commissioning which include:

• Cost savings
• Energy savings
• Improved equipment performance
• Better occupant comfort and indoor air quality
• Increased O&M staff capabilities and expertise
• Increased asset value

If this wasn't enough of a case for retro-commissioning, it is reported by the U.S. Energy Information Administration that if all existing U.S. commercial buildings were retro-commissioned and all new buildings were commissioned, their collective energy bill would be reduced by $18 billion a year! Although cars are mass produced, buildings are one-of-a-kind, which makes it even more important to "kick the tires" before signing on the dotted line. Don't get stuck with a lemon!

An Ounce of Performance is Worth Pounds of Promises

Have you heard the saying, "Being first is not always best"? The same can be said for being new. There are many instances of new products and services that have failed miserably…New Coke, Blackberry PlayBook and Windows Vista come to mind. In some cases, people wait for the next best thing while others return to the tried-and-true. 

We also see this happen in the energy efficiency and conservation industry when a new building does not meet performance expectations. Whether it is a school, fire station or office, a new building is a symbol of growth, expansion and success. But in today's environmentally-conscious world, it should also symbolize energy efficiency and sustainability leadership.

However, what happens if the new building turns out to have continuous maintenance problems and energy bills higher than one built 20 years earlier? What should be an energy-saving showplace can quickly turn into an uncomfortable work environment, money drain, and embarrassment.

It is way too common for schools, or any other entity for that matter, to build a new facility and it is the worst performing school in the district. The reasons are many:

• Too complicated 
• Never properly commissioned 
• Energy efficiency was “value engineered” out 
• Most importantly, no single entity is accountable. The architect points the finger at the engineer, who points it at the mechanical contractor, who points it at the controls contractor, who points it at the engineer, who points it at the budget, and so on. 

How can you prevent this from happening? 

The truth is, while everyone wants a green school or eco-friendly office, it takes a commitment from all parties involved to make it happen. Establishing and implementing aggressive energy performance goals during the design and construction of new commercial buildings is important to achieving those goals over the lifetime of the building. We have worked with more than 27 school districts throughout Texas on energy savings projects and these are the top five things to consider when constructing a new building:

1. Preserve the budget for energy efficiency: Typically the first things to get cut are the things that will save you the most in the long run.
2. Staff: Don’t design systems that are unique and complicated if your staff is accustomed to simple and straightforward.
3. Demand robust commissioning: The most common culprit in any new building being an energy waster is the system not operating as it was designed.
4. Training: Today’s energy saving buildings can be complicated, and your staff needs the knowledge to master their new tools, not be overwhelmed by them.
5. Make someone accountable: Structure your project in such a way that finger-pointing is impossible. Design-build is a good option if you have a good contractor. 

At the end of the day, it comes down to results. Are your students or employees comfortable? Does your HVAC equipment work like it should? Did your contractor deliver? Although an unlikely source, we think this quote from Mae West sums it up perfectly: "An ounce of performance is worth pounds of promises."