New Albany-Plain Local Schools LED Funded Boiler Replacement - - PowerPoint PPT Presentation
New Albany-Plain Local Schools LED Funded Boiler Replacement Discussion Document Lucas Dixon Dave Zehala Jarret Kelley Energy Manager President Director of Engineering lucas.dixon@plugsmart.com dave.zehala@plugsmart.com
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Lucas Dixon Dave Zehala Jarret Kelley
Energy Manager President Director of Engineering lucas.dixon@plugsmart.com dave.zehala@plugsmart.com jarret.kelley@plugsmart.com (614) 580-3352 (614) 935-7487 (614) 230-7256
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Plug Smart is an Ohio based company with offices in Columbus, Cincinnati, Dayton, Cleveland, and branch offices in Kentucky, Tennessee and Florida Design-build project developer that specializes in developing self-funding energy projects Turnkey controls contracting services including: Engineering services Project management Equipment procurement Performance guarantees Business model custom tailored for school clients Subcontractor choice Vendor neutral approach Best-value solutions Energy savings guarantee
K-12 Clients and Partners
Ohio K-12 Clients
Columbus
Cincinnati Cleveland
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Key Accounts Include
Adams County Ohio Valley Local Schools Amanda-Clearcreek Local Schools Archbold Area Local Schools Ashland City Schools Austintown Local Schools Barberton City Schools Beavercreek City Schools Benton Carroll Salem Local Schools Berne Union Local Schools Bexley City Schools Bristol Local Schools Brooklyn City Schools Cabel County Schools Calvert Catholic Schools Cambridge City Schools Canfield Local Schools Canton City Schools Carrollton Exempted Village Schools Centerburg Local Schools Cincinnati Public Schools Clear Fork Valley Local Schools Clinton-Massie Local Schools Collins Career Center Lawrence County Columbus City Schools Columbus Grove Local Schools Copley-Fairlawn City Schools Danville Local Schools Dawson-Bryant Local Schools Defiance City Schools East Clinton Local Schools East Knox Local Schools East Liverpool City Schools Edison Local (Jefferson) Schools Elyria City Schools Fairfield City Schools Fairfield Union Local Schools Fairless Local Schools Fairview Park City Schools Findlay City Schools Franklin Local Schools Gallipolis City Schools Garfield Heights City Schools Geneva Area City Schools Georgetown Exempted Village Schools Girard City Schools Goshen Local Schools Granville Exempted Village Schools Green Local (Summit) Schools Greenon Local Schools Hamilton Local Schools Hillsboro City Schools Howland Local Schools Huber Heights City Schools Huron City Schools Jackson City Schools James A. Garfield Local Schools Johnstown-Monroe Local Schools Jonathan Alder Local Schools Kings Local Schools Lake Local (Stark) Schools Lakota Local (Butler) Schools Lebanon City Schools Lee County Schools Leetonia Exempted Village Schools Little Miami Local Schools London City Schools Louisville City Schools Madeira City Schools Manatee County Schools Mapleton Local Schools Marion City Schools Marlington Local Schools Mason City Schools Miamisburg City Schools Middletown City Schools Miller City-New Cleveland Local Schools Mount Healthy City Schools Mount Vernon City Schools Nelsonville-York City Schools New Lebanon Local Schools North Canton City Schools North Olmsted City Schools North Royalton City Schools Northmont City Schools Northridge Local (Licking) Schools Norton City Schools Oak Hill Union Local Schools Olmsted Falls City Schools Ottawa Hills Local Schools Pettisville Local Schools Pickaway-Ross County Career and Tech Center Polaris Career Ctr Princeton City Schools Revere Local Schools Reynoldsburg City Schools River Valley Local Schools Riverside Local (Lake) Schools Sebring Local Schools Seminole County Schools Southeastern Local (Clark) Schools Southeastern Local (Ross) Schools Southern Local (Perry) Schools Springboro City Schools St Vincent Catholic School Stow-Munroe Falls City Schools Strasburg-Franklin Local Schools Strongsville City Schools Trotwood-Madison City Schools Tuslaw Local Schools Twinsburg City Schools Union Scioto Local Schools Upper Arlington City Schools Upper Scioto Valley Local Schools Vandalia-Butler City Schools Wadsworth City Schools Warren County Career Center Washington Court House City Schools Washington Local Schools Wellston City Schools West Holmes Local Schools West Jefferson Local Schools Willard City Schools Williamsburg Local Schools Willoughby-Eastlake City Schools Wilmington City Schools Windham Exempted Village Schools
Total industry experience Ohio School Districts Served Energy Savings Pounds of CO2 Saved
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Project Objective
Develop a self-funding project that utilizes the savings from a high efficiency LED project to help self-fund a planned boiler replacement program throughout the district.
Boiler Replacement Assessment
Every boiler plant was evaluated with respect to efficiency, load/size, age, and ease of access. District stakeholders were also interviewed in order to collect a comprehensive record of historical maintenance issues and expenditures. Upon completion, each plant was prioritized based on six key criteria: existing issues, lifecycle stage, size and redundancy, access, critical area(s) served, and operational savings potential.
Lighting Retrofit Assessment
Every light fixture was audited from the electrical prints followed by an on-site assessment. The goal was to identify maximum ROI opportunities while also highlighting key areas for enhanced lighting upgrades and/or improved lighting design.
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Boiler Category High School Middle School Intermediate School Primary School Early Learning Center A, B, and C D E, F, and G H and I J, K, and L Year Installed (Age)
1995 (24) 1995 (24) 1995 (24) 1995 (24) 2003 (16) 2001 (18) 2014 (5) 1999 (20) 2002 (17)
Size in MBH (Redundancy)
2,000 (2) 5,000 (2) 1,500 (2) 1,200 (2) 2,500 (2) 7,000 (2) 4,000 (2) 6,000 (2) 2,500 (2)
Utility Rate $/MMBTU
4.80 4.80 4.80 4.80 4.80 4.77 6.18 4.95 5.08
System Access
First floor mechanical room off of pool First floor mechanical room with easy access Third floor mechanical room, standard man- door access Second floor mechanical room. First floor mechanical room, standard man- door access Third floor mechanical room, standard man- door access; First floor mechanical room First floor mechanical room First floor mechanical room, double door access
Critical Area Served
Buildings A, B, and C (athletic / non-ed. space) Weight room (athletic / non- educational space) Academic buildings E, F, and G Buildings H (library) and I (arts & music) Academic buildings J, K, and L Middle School academic areas, gym, and cafeteria Intermediate academic areas Primary academic areas (2-5) Early Learning Center academic areas (K-1)
Known Issues
Part of oldest group of boilers. Grossly oversized; Cycle frequently, reduced efficiency; Part of
Issues include burnout issues on the shells; Part of
boilers No dedicated combustion air; Issues include burnout issues on the shells Two-story building with flues through roof, generally functional One third of tubes replaced in one boiler, concern on
RBI Futura boilers are newest in district, minimal issues Minimal issues Minimal issues
Proposed Solution
(2) 1,600 MBH Output Condensing Boilers (2) 1,000 MBH Output Condensing Boilers; Smaller pump, header (2) 1,250 MBH Output Condensing Boilers (2) 1,000 MBH Output Condensing Boilers (2) 2,500 MBH Output Condensing Boilers (2) 6,000 MBH Output Condensing Boilers (2) 3,500 MBH Output Condensing Boilers (2) 6,000 MBH Output Condensing Boilers (2) 2,500 MBH Output Condensing Boilers
NAPLS Benefits
Modulating Burners Higher combustion efficiency Lower Return Temperatures Smaller Footprint
Total Boilers: Average Boiler Age: Average Boiler Energy Reduction: Metric Tons of CO2 Offset:
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Boiler Category High School Middle School Intermediate School Primary School Early Learning Center A, B, and C D E, F, and G H and I J, K, and L Number of Fixtures
548 91 1,178 525 919 2,127 797 1,674 1,040
Technology Mix
T8 (60%), CFL (13%), MH (12%), T5 (7%), Exits (6%), LED (3%) T8 (56%), T5 (18%), LED (11%), Inc (7%), CFL (7%) T8 (89%), CFL (6%), Inc (3%), Halogen (1%), LED (1%) T8 (71%), CFL (12%), MH (12%), Halogen (4%), LED (2%) T8 (77%), CFL (11%), LED (10%), T12 (1%), Inc (<1%) T8 (86%), CFL (7%), T5 (3%), Inc (3%), MH (<1%) T8 (72%), LED (16%), T5 (11%), CFL (1%) T8 (83%), CFL (13%), MH (2%), Inc (1%) T8 (83%), CFL (13%), MH (2%), Inc (1%)
Utility Rate $/kWh
0.089 0.089 0.099 0.092 0.099 0.107 0.106 0.120 0.110
Existing Conditions Comments
Gym and lobby still metal halide; Wrestling room already LED Weight room has 54W T5 High bay fixtures with
Over 2,600 tubes; lift access needed for 30’ hallway fixtures; Library cove lights not working. LED Theatre lights inconsistent color
and choir rooms. Dimming fluorescent ballasts cause flickering issues; Over 1,700 tubes; Jefferson room has 4-lamp PLL lamps. Over 4,700 tubes; Staff runs 2/3 lamps in cafeteria areas; Cove lights are not easy to change. Newest school, so highest % already LED (including gym). Corridors have 54W T5 and direct/indirect fixtures. Gym has (24) 400W MH and (6) 250W MH fixtures. Over 3,600 tubes throughout; Cover lights are not easy to change. Over 2,300 tubes throughout; Occ sensors already
already upgraded to LED; Gym has (24) 4L T5 fixtures;
Proposed Solution Comments
Upgrade all fixtures to Tier-1 LED, occupancy sensors in gym and main restrooms Retrofit with direct-wired LED tubes, occupancy sensors in weight room Retrofit with direct-wired LED tubes, occupancy sensors in main restrooms Replace existing with LED fixtures,
in main restrooms Retrofit with direct-wired LED tubes, new LED fixtures in cafeteria Retrofit with direct-wired LED tubes, occupancy sensors in main restrooms and gym Direct-wired LED T5/T8 lamp replacements Retrofit with direct-wired LED tubes, new fixtures and
in gym Replace fixtures and add
in gym
NAPLS Benefits 50% savings over T8 Long equipment life (25+ years) Reduces system O&M costs Improved learning environment Total fixtures: Average Lighting Energy Reduction: Total Watts Reduced: Metric Tons of CO2 Offset:
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*Rebates pending utility approval; Grants are first come, first serve and must be spent summer of 2019
GMAX (w/rebate) Utility Rebate Utility O&M Total
1 LED Upgrades: ABCD $ 101,211 $ 5,146 $ 7,255 $ 1,900 $ 9,155 11.1 2 LED Upgrades: EFG, JKL $ 139,509 $ 9,859 $ 13,933 $ 2,787 $ 16,719 8.3 3 LED Upgrades: H $ 26,776 $ 2,994 $ 2,511 $ 1,179 $ 3,690 7.3 4 LED Upgrades: I $ 14,080 $ 860 $ 2,951 $ 590 $ 3,541 4.0 5 LED Upgrades: MS $ 178,469 $ 18,301 $ 21,622 $ 5,195 $ 26,817 6.7 6 LED Upgrades: Int. $ 47,237 $ 10,479 $ 8,119 $ 2,426 $ 10,545 4.5 7 LED Upgrades: Primary $ 124,380 $ 14,731 $ 19,608 $ 4,721 $ 24,329 5.1 8 LED Upgrades. ELC $ 80,951 $ 8,231 $ 5,715 $ 2,927 $ 8,642 9.4 9 LED Upgrades: Exterior $ 66,726 $ 7,813 $ 18,222 $ 5,467 $ 23,688 2.8 10 Boiler Upgrades: C 5 $ 151,941 $ 1,632 $ 804 $ 1,231 $ 2,035 74.6 11 Boiler Upgrades: D 4 $ 157,657 $ 4,079 $ 2,011 $ 1,426 $ 3,437 45.9 12 Boiler Upgrades: E 2 $ 147,343 $ 1,224 $ 603 $ 1,942 $ 2,545 57.9 13 Boiler Upgrades: I 3 $ 139,821 $ 979 $ 483 $ 1,763 $ 2,246 62.3 14 Boiler Upgrades: J 8 $ 187,630 $ 2,129 $ 1,050 $ 1,688 $ 2,738 68.5 15 Boiler Upgrades: MS 1 $ 349,216 $ 5,564 $ 2,726 $ 2,984 $ 5,710 61.2 16 Boiler Upgrades: Int. 9 $ 216,968 $ 1,574 $ 999 $ 300 $ 1,299 167.1 17 Boiler Upgrades: Primary 6 $ 313,280 $ 4,636 $ 2,357 $ 1,147 $ 3,504 89.4 18 Boiler Upgrades: ELC 7 $ 180,150 $ 3,294 $ 1,719 $ 943 $ 2,662 67.7 SG1 State Grant Offset 1
N/A SG2 State Grant Offset 2
N/A $ 2,543,347 $ 183,528 $ 112,687 $ 40,615 $153,302 16.6 Energy Conservation & Facility Improvement Measures Financial Analysis Priority Total Measure Investment Annual Savings Simple Payback
(years)
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*Rebates pending utility approval; Grants are first come, first serve and must be spent summer of 2019
GMAX (w/rebate) Utility Rebate Utility O&M Total
1 LED Upgrades: ABCD $ 101,211 $ 5,146 $ 7,255 $ 1,900 $ 9,155 11.1 2 LED Upgrades: EFG, JKL $ 139,509 $ 9,859 $ 13,933 $ 2,787 $ 16,719 8.3 3 LED Upgrades: H $ 26,776 $ 2,994 $ 2,511 $ 1,179 $ 3,690 7.3 4 LED Upgrades: I $ 14,080 $ 860 $ 2,951 $ 590 $ 3,541 4.0 5 LED Upgrades: MS $ 178,469 $ 18,301 $ 21,622 $ 5,195 $ 26,817 6.7 6 LED Upgrades: Int. $ 47,237 $ 10,479 $ 8,119 $ 2,426 $ 10,545 4.5 7 LED Upgrades: Primary $ 124,380 $ 14,731 $ 19,608 $ 4,721 $ 24,329 5.1 8 LED Upgrades. ELC $ 80,951 $ 8,231 $ 5,715 $ 2,927 $ 8,642 9.4 9 LED Upgrades: Exterior $ 66,726 $ 7,813 $ 18,222 $ 5,467 $ 23,688 2.8 10 Boiler Upgrades: C 5 $ 151,941 $ 1,632 $ 804 $ 1,231 $ 2,035 74.6 11 Boiler Upgrades: D 4 $ 157,657 $ 4,079 $ 2,011 $ 1,426 $ 3,437 45.9 12 Boiler Upgrades: E 2 $ 147,343 $ 1,224 $ 603 $ 1,942 $ 2,545 57.9 13 Boiler Upgrades: I 3 $ 139,821 $ 979 $ 483 $ 1,763 $ 2,246 62.3 14 Boiler Upgrades: J 8 $ 187,630 $ 2,129 $ 1,050 $ 1,688 $ 2,738 68.5 15 Boiler Upgrades: MS 1 $ 349,216 $ 5,564 $ 2,726 $ 2,984 $ 5,710 61.2 16 Boiler Upgrades: Int. 9 $ 216,968 $ 1,574 $ 999 $ 300 $ 1,299 167.1 17 Boiler Upgrades: Primary 6 $ 313,280 $ 4,636 $ 2,357 $ 1,147 $ 3,504 89.4 18 Boiler Upgrades: ELC 7 $ 180,150 $ 3,294 $ 1,719 $ 943 $ 2,662 67.7 SG1 State Grant Offset 1
N/A SG2 State Grant Offset 2
N/A $ 1,335,720 $ 166,183 $ 103,747 $ 33,880 $137,628 9.7 Energy Conservation & Facility Improvement Measures Financial Analysis Priority Total Measure Investment Annual Savings Simple Payback
(years)
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Assumption: Utility and O&M costs escalate at 3% per year
Financed Amount Interest Rate Loan Term $1,769,341 5.50% 20 Energy O&M Total Annual Cumulative Savings Savings Savings Cash Cash Flow Flow 1 $103,747 $33,880 $137,628 $110,259 $27,369 $27,369 2 $106,860 $34,897 $141,757 $110,259 $31,498 $58,866 3 $110,066 $35,944 $146,009 $110,259 $35,750 $94,617 4 $113,368 $37,022 $150,390 $110,259 $40,131 $134,747 5 $116,769 $38,133 $154,901 $110,259 $44,642 $179,390 6 $120,272 $39,277 $159,548 $110,259 $49,289 $228,679 7 $123,880 $40,455 $164,335 $110,259 $54,076 $282,755 8 $127,596 $41,669 $169,265 $110,259 $59,006 $341,760 9 $131,424 $42,919 $174,343 $110,259 $64,084 $405,844 10 $135,367 $44,206 $179,573 $110,259 $69,314 $475,158 11 $139,428 $45,532 $184,960 $110,259 $74,701 $549,860 12 $143,611 $46,898 $190,509 $110,259 $80,250 $630,110 13 $147,919 $48,305 $196,224 $110,259 $85,965 $716,075 14 $152,357 $49,754 $202,111 $110,259 $91,852 $807,927 15 $156,927 $51,247 $208,174 $110,259 $97,915 $905,842 16 $161,635 $52,784 $214,420 $110,259 $104,161 $1,010,003 17 $166,484 $54,368 $220,852 $110,259 $110,593 $1,120,596 18 $171,479 $55,999 $227,478 $110,259 $117,219 $1,237,815 19 $176,623 $57,679 $234,302 $110,259 $124,043 $1,361,858 20 $181,922 $59,409 $241,331 $110,259 $131,072 $1,492,930 Totals $2,787,733 $910,377 $3,698,110 $2,205,180 $1,492,930 $1,492,930 Total
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Assumption: Utility and O&M costs escalate at 3% per year
Financed Amount Interest Rate Loan Term $1,335,720 0.00% 1 Energy O&M Total Annual Cumulative Savings Savings Savings Cash Cash Flow Flow 1 $103,747 $33,880 $137,628 $1,335,720 ($1,198,093) ($1,198,093) 2 $106,860 $34,897 $141,757 $0 $141,757 ($1,056,336) 3 $110,066 $35,944 $146,009 $0 $146,009 ($910,327) 4 $113,368 $37,022 $150,390 $0 $150,390 ($759,937) 5 $116,769 $38,133 $154,901 $0 $154,901 ($605,036) 6 $120,272 $39,277 $159,548 $0 $159,548 ($445,487) 7 $123,880 $40,455 $164,335 $0 $164,335 ($281,153) 8 $127,596 $41,669 $169,265 $0 $169,265 ($111,888) 9 $131,424 $42,919 $174,343 $0 $174,343 $62,455 10 $135,367 $44,206 $179,573 $0 $179,573 $242,028 11 $139,428 $45,532 $184,960 $0 $184,960 $426,988 12 $143,611 $46,898 $190,509 $0 $190,509 $617,497 13 $147,919 $48,305 $196,224 $0 $196,224 $813,722 14 $152,357 $49,754 $202,111 $0 $202,111 $1,015,833 15 $156,927 $51,247 $208,174 $0 $208,174 $1,224,007 16 $161,635 $52,784 $214,420 $0 $214,420 $1,438,427 17 $166,484 $54,368 $220,852 $0 $220,852 $1,659,279 18 $171,479 $55,999 $227,478 $0 $227,478 $1,886,757 19 $176,623 $57,679 $234,302 $0 $234,302 $2,121,059 20 $181,922 $59,409 $241,331 $0 $241,331 $2,362,390 Totals $2,787,733 $910,377 $3,698,110 $1,335,720 $2,362,390 $2,362,390 Total
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Performance contracting provides
International Performance Measurement and Verification Protocol was created in 1995 by DOE and others OFCC adopted IPMVP standards as part
Not as simple as comparing bills from year to year as too much can change:
Predominate method used in Ohio K-12
(Lighting Retrofit, Power Draw, Estimate Hours Operation)
(Building controls, multivariate regression analysis)
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Qualified
One of the largest dedicated, multi-platform controls contracting teams in the State of Ohio
Experienced
Over 550 man-years company-wide
installation, project management, and services experience.
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Evaluated Boilers & Lighting
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2019
Today Apr May Jun Jul Aug Sep Oct
Contract Award
Apr 15
Warranty Start
Oct 2 Apr 26 Apr 28
Pr Proje ject Kickoff
Apr 29 May 13
ngineer ering
May 13 Jun 22
II.
rocurement
May 13 May 20
Bo Boilers
May 13 Jun 22
Lighting
May 13 May 27
III
ubcontracting
May 13 May 27
Lighting
May 13 May 20
Bo Boilers
Jun 3 Sep 22
IV.
Installation
Jun 3 Sep 1
Lighting
Jul 24 Sep 22
Bo Boilers
Sep 24 Oct 1
V. . Commissioning
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Maintenance Issue Has this equipment had recent or historical maintenance issues. End of Life Is this equipment past its useful life. Sizing/Redundancy Does the plant have redundancy or is it oversized. Access How difficult is it to fix/replace this unit. Harder to access = Costlier unplanned fix. Critical Area Served Does this serve classrooms.
1 MS Cafeteria (2) CB FLX 700- 550 MS, HS/MS Cafeteria, MS Gym 80% 7,000 IN 5,600 OUT 2001 (18)
5 3 1 5 5 4
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2 HS: Building E (2) Bryan AB150- W-FDG HS E,F,G 80% 1,500 IN 1,200 OUT 1995 (24)
4 5 1 4 4 4
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3 HS: Building I (2) Bryan AB120- W-FDG HS H, I (library, arts) 80% 1,200 IN 960 OUT 1995 (24)
4 5 1 3 3 4
20
4 HS: Building D (2) Bryan HS D (weight room) 80% 5,000 IN 4,000 OUT 1995 (24)
2 5 5 1 2 5
20
5 HS: Building C (2) Bryan HS A,B,C (pool, gym) 80% 2,000 IN 1,600 OUT 1995 (24)
4 5 1 1 3 4
18
6 Primary (2) CB FLX 700 2-5 Primary 80% 6,000 IN 4,800 OUT 1999 (20)
3 4 1 1 5 4
18
7 ELC (2) Bryan AB250- W-FDG ELC 80% 2,500 IN 2,000 OUT 2002 (17)
3 2 1 1 5 4
16
8 HS: Building J (2) Bryan AB250- W-FDG HS J,K,L 84% 2,500 IN 2,088 OUT 2003 (16)
3 2 1 2 4 3
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9 Intermediate (2) RBI Futura MB4000 Intermediate 87% 4,000 IN 3,480 OUT 2014 (5)
1 1 1 1 5 1
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Boiler Plant Existing
Age (Years) Efficiency Serves Size
Access End of Life Sizing/ Redundancy Critical Area Served Ops Savings Overall Score
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Energy Snapshot
Simplified Condensing Boiler Steady-State Thermal Efficiency as a Function of Return Water Temperature
water temperature to the boilers. The lower this temperature, the more the flue gases are able to condense and the higher the combustion efficiency.
without shortening the life of the heat exchanger and therefore must be kept above 140°F HW temp.
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0.00 200.00 400.00 600.00 800.00 1,000.00 1,200.00 1,400.00 1,600.00 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0
Monthly Gas Usage (MMBTU) Average Monthly Outside Air Temp (F)
Gas Usage VS. Average Monthly Temp
2018 2017 2016
Calculation Snapshot: Middle School The weather-based regression has a 95% R2, meaning that weather can predict natural gas usage with 95% accuracy. Non Weather-Dependent Usage Heating Usage
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Min in: 42.9 42.9 fc Max: 69.1 69.1 fc Avg: 61.9 61.9 fc