Energy Audit Report For Fitness and Recreation center (Gym)

Submitted by Niranjan Ramamurthy

Spring 2012

Energy Audit report for Fitness and Recreation center (Gym)

Executive Summary
As part of an initiative to reduce energy cost and consumption, Purdue University Calumet (PUC) has secured the services of School of Engineering, Maths & Science (EMS) to perform an energy audit for their Fitness and Recreation center (Gym) in an effort to develop comprehensive Energy Conservation and Retrofit Measures (ECRMs). EMSs energy audit team visited the gym on February 2nd, 2012. As a result of the site visits and evaluation of the historical energy usage of the facility, EMS was successful in identifying various activities of the gym and building system components that present feasible opportunities for energy savings measures.

EMS has also evaluated the potential for electrical energy usage. Specifically, the use of Metal Halide lighting systems which can be replaced with Induction Fluorescent lighting systems which provides better lighting and are maintenance free, the average life hours is estimated to be 1,00,000 hours and saves up to 67% energy savings over HPS and metal halide.

The team has also come up with an idea to add a lining to the exterior metal doors in order to prevent heat loss from the sides of the door which was found form the images from IR camera. We have recommended to go with 1/8th inch thick thermal sealing adhesive tapes for the side areas of the doors and transom seal for the bottom portion of the doors and saves up to 46% of the heat lost from doors, thereby saving up to 15% of the energy.

It was also found that by updating the thermostat we will be able to control the temperature of the gymnasium in a better way and will be able to remove the use of compressor.

In addition, EMS has come up with proposals to introduce Economizer for the boiler which increases the boiler efficiency which will also be best energy cost saving. A generally accepted "rule of thumb" is that about 5% of boiler input capacity can be recovered with a properly sized economizer. It has also been noticed from the IR images of the boiler shows heat escape from the boiler and it is recommended to replace the boiler lining so as to decease the heat lost from the boiler. Department of Mechanical Engg, Purdue University Calumet Page 2

Energy Audit report for Fitness and Recreation center (Gym) Not all ECRMs identified as a result of the energy audit are recommended. We have chosen the ECRMs which are economically feasible to be recommended to the University for Implementation. The feasibility of each ECRM was measured through a simple payback analysis. The simple payback period was determined after establishing Engineers Opinion of Probable Construction Cost estimates, O&M estimates, projected annual energy savings estimates, and the potential value of New Jersey Clean Energy rebates, or Renewable Energy Credits, if applicable. ECRMs with a payback period of 20 years or less are recommended. Recommended ECRMs The following table, Table ES-1, presents the ranking of recommended ECRMs identified for treatment processes and equipment and various building system components at the wastewater and water treatment and pumping facilities. Additional ECRMs were identified and evaluated, as discussed in Section 4; however, were not recommended due to longer payback periods. Table ES-1 includes the Engineers Opinion of Probable Construction Cost, projected annual energy cost savings, projected annual energy usage savings, and total simple payback period for each recommended ECRM. The ECRMs are ranked based on their simple payback period.

Ranking 1 2 3 4

Type Lighting Door Insulation Economizer Thermostat

Initial cost diff. Operating cost savings Simple payback 30,000 500 2850 90 2900 275 1150 90 10.3 yrs. 1.8 yrs. 2.5 yrs. 1.0 yrs.

Table shows the ranking of different ECOs recommended from energy audit

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Energy Audit report for Fitness and Recreation center (Gym)

Table of contents
1: Introduction 1.1: Purpose of the energy audit 1.2: Need for a continuing energy cost control program 2: Facility Description 2.1: Product or service, and materials flow 2.2: Size, construction, facility layout, and hours of operation 2.3: Equipment list, with specifications 3: Energy Bill Analysis 4: Utility rate structures 4.1: Tables and graphs of energy consumptions and costs 4.2: Discussion of energy costs and energy bills 5: Energy Conservation Opportunities 5.1: Listing of potential ECOs 5.2: Cost and savings analysis 5.3: Economic evaluation 6: Action Plan 6.1: Recommended ECOs and an implementation schedule 6.2: Designation of an energy monitor and ongoing program

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Energy Audit report for Fitness and Recreation center (Gym)

Section 1: Introduction
1.1 Purpose of the energy audit report
As part of an initiative to reduce energy cost and consumption, Purdue University Calumet (PUC) has secured the services of School of Engineering, Maths & Science (EMS) to perform an energy audit for their Fitness and Recreation center (Gym) in an effort to develop comprehensive energy conservation initiatives.

The performance of an Energy Audit requires a coordinated phased approach to identify, evaluate and recommend energy conservation and retrofit measures (ECRM). The various phases conducted under this Energy Audit included the following: Gather preliminary data on all facilities; Facility inspection; Identify and evaluate potential ECRMs and evaluate renewable/distributed energy Measures. Develop the energy audit report.

Figure 1-1 is a schematic representation of the phases utilized by CDM to prepare the Energy Audit Report.

Facility Inspection Gather primary data Energy Bills Facility Description Facility Operating hours Detailed equipment lists Lighting Building Shell Boiler room HVAC systems Hot air distribution systems Electrical supply systems Hot air circulation system Identifying and evaluating

Energy Audit Report

Fig: 1 shows the general steps followed during energy audit Department of Mechanical Engg, Purdue University Calumet Page 5

Energy Audit report for Fitness and Recreation center (Gym)

Section 2: Facility description 2.1 The Fitness and Recreation center

The Purdue Calumet Fitness & Recreation Center is home to the Peregrine volleyball and mens and womens basketball teams. The Fitness & Rec Center also houses offices and conference rooms for PUC athletics along with two racquetball courts, locker rooms, a running track. The gym floor was renovated in the summer of 2011 with a complete redesign and the addition of several new features due to rule changes in the NAIA and the NCAA. The universitys Fitness Center, under the direction of John Bobalik, is also housed in the building. The Fitness Center is a comprehensive, multi-dimensional physical fitness training facility designed to service Purdue Calumet students, faculty, staff and people from the surrounding communities.

Purdue Calumet announced a ground-breaking agreement with the City of Hammond in March 2011 to develop Dowling Park (located just north of I80-94 on Kennedy Avenue) into a comprehensive outdoor sports complex for both Peregrine Athletics and the Hammonds Parks and Recreation Department. The new athletic facility will house the playing fields for the Black and Golds baseball, mens & womens soccer, softball and mens & womens tennis teams.

2.2 Size, construction, facility and hours of operation

The objective of the energy audit is to identify energy conservation and retrofit measures to reduce energy usage and to develop an economic basis to financially validate the planning and implementation of identified energy conservation and retrofit measures.

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Energy Audit report for Fitness and Recreation center (Gym)

Section 3: Energy bill analysis for Fitness & Recreation Center (Gym)
Month kWh used kWh cost ($) Demand (kW) Demand cost ($) Total cost ($)

March 2011 April 2011 May 2011 June 2011 July 2011 August 2011 September 2011 October 2011 November 2011 December 2011 January 2012 February 2012

450 444 436 445 449 421 439 450 450 451 449 448

1468 1448 1422 1451 1465 1373 1432 1468 1468 1471 1465 1461

25 20 18 19 17 16 16 16 18 19 20 22

178 142 128 135 121 114 114 114 128 135 142 156

1646 1590 1550 1586 1586 1487 1546 1582 1596 1606 1607 1617

Table 3.1 shows the energy bill analysis of gymnasium from March 2011 to February 2012.

Note: 1. No. of units = 63 2. Watt per unit = 800W 3. Price per kilo watt hour = $0.06732 (Approx) 4. Demand cost for per kilo watt hour = $7.1 (Approx) 5. The area is heated in winter and is not cooled in summer. 6. The formula for calculating the cost of running a device Cost of electricity = Wattage * Hours used / 1000 * price per kWh

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Energy Audit report for Fitness and Recreation center (Gym)

kWh demand Vs Months

455 450 445 440 435 430 425 420 415 410 405

kWh used

Fig 3.1 shows the bar graph of kWh vs. months

Total cost ($) Vs Months

1650 1600 1550 1500 1450 1400 Total cost ($)

Fig 3.2 shows the bar graph of total cost vs. months

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Energy Audit report for Fitness and Recreation center (Gym)

Demand (kW) Vs Months

25 20 15 10 5 0 Demand (kW)

Fig 3.1 shows the bar graph of demand kW vs. months

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Energy Audit report for Fitness and Recreation center (Gym)

Section 4: Utility rate structure

Many utilities are starting to plan for changes in their utility rates for 2006. The following information is presented in response to requests from readers to provide a summary of the types of water rate structures most often used. This overview can be shared with decision makers to help facilitate discussion regarding the most desirable rate structure for your utility. Flat Fee is a rate structure where all customers are charged the same fee, regardless of the volume of water used. A flat fee does not take into account the cost of providing service to various user classes or encourage reasonable water use through increased costs for increased usage. A flat fee is simple and can provide stability through knowing the revenue that will be generated per household. Constant Block (Uniform Rates) is a structure that has a constant unit price for all metered volumetric units of water consumed on a year-round basis. It differs from a flat fee in that it requires metered service. Constant block rates are appropriate when the cost of providing the service is generally the same across all user classes, although multiple constant blocks can be utilized for multiple user classes. Constant block rates provide some stability for utilities and encourage conservation because the costumer bills vary with water usage. Declining Block Rates is a rate structure in which the unit price of each succeeding block of usage is charged at a lower unit rate than the previous block(s). Declining block rates are designed to recover the costs of serving different classes of costumers while maintaining reasonable equity among the costumer classes. Declining block rates assume that customers that have a higher demand also have a more predictable peak demand than do smaller customers. Thus they receive a discounted rate for the higher volumes that they use. Declining block rates do not, however, promote conservation, and many utilities are moving away from this rate structure. Increasing Block Rates is a rate structure in which the unit price of each succeeding block of usage is charged at a higher unit rate than the previous block(s). Increasing block rates are designed to promote conservation. While this can be beneficial, it is also harder for a utility to predict revenues from seasonal consumption. When the rate for additional usage is high, costumers may cut usage, and the utility may experience reduced revenues.

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Energy Audit report for Fitness and Recreation center (Gym)

Section 5: Energy conservation opportunities

5.1: Listing of potential ECOs
Lighting Alternative Induction Fluorescent lighting systems Induction Canopy Light - 120 Watt

Wattage : 120 Voltage : 277 Bulb Type : 120W Bulb(s) Included : Yes Metal Halide Equal : 175 Watt Life Hours : 100,000 Lumens (Initial) : 9600

Long lifespan due to the lack of electrodes - between 65,000 and 100,000 hours depending on the lamp model High power factor due to the low loss in high frequency electronic ballasts which are between 95% and 98% efficient Minimal Lumen depreciation (declining light output with age) compared to other lamp types as filament evaporation and depletion is absent Instant-on and hot re-strike, unlike most conventional lamps used in commercial/industrial lighting applications (High Pressure Sodium and Metal Halides) Environmentally friendly as induction lamps use less energy, and generally use less mercury per hour of operation that conventional lighting due to their long lifespan. The mercury is in a solid form and can be easily recovered if the lamp is broken, or for recycling at end-of-life

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Energy Audit report for Fitness and Recreation center (Gym)

Induction Wall Pack - 100 Watt

Wattage: 100 Voltage: 277 Bulb Type: 100W Bulb(s) Included: Yes Metal Halide Equal: 150 Watt Life Hours: 100,000 Lumens (Initial): 8000

Long lifespan due to the lack of electrodes between 65,000 and 100,000 hours depending on the lamp model High power factor due to the low loss in high frequency electronic ballasts which are between 95% and 98% efficient Minimal Lumen depreciation (declining light output with age) compared to other lamp types as filament evaporation and depletion is absent Instant-on and hot re-strike, unlike most conventional lamps used in commercial/industrial lighting applications (High Pressure Sodium and Metal Halides) Environmentally friendly as induction lamps use less energy, and generally use less mercury per hour of operation that conventional lighting due to their long lifespan. The mercury is in a solid form and can be easily recovered if the lamp is broken, or for recycling at end-of-life.

Thermostat Alternative
Honeywell Vision PRO 8000 Thermostat

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Energy Audit report for Fitness and Recreation center (Gym) Real-Time Clock-keeps time during power failures & updates automatically for daylight savings Change/Check Reminders- alerts when you need to replace batteries, filters, or service is needed Precise Comfort Control - +/- 1 degree Fahrenheit Programmable Fan Energy Star Rating 5 Year Warranty Touch Screen Interaction Up to 7 Day Programmability Permanent Memory Retention Adaptive Intelligent Recovery Dual Powered - Battery and Hardwire Takes 3 AAA Batteries

Introducing Economizer
How They Work Boiler stack economizers are simply heat exchangers with hot flue gas on one side and water on the other. Or, in direct contact condensing units, the make-up water is in direct contact with the flue gases. Economizers must be sized for the volume of flue gas, its temperature, the maximum pressure drop allowed through the stack, what kind of fuel is used in the boiler, and how much energy needs to be recovered. Economizers designed for natural gas only, would likely plug-up if installed on a coal boiler and would face increased risk of corrosion if installed on an oil-fired boiler. Some units are designed to keep the flue gases above condensation temperature, and others are made of materials that resist the corrosive effect of condensed flue gases.

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Energy Audit report for Fitness and Recreation center (Gym)

Fig 5.1 shows the schematic representation of boiler with economizer Economics The savings potential is a function of how much heat can be recovered, which is a function of how much cold water needs to be heated. A generally accepted "rule of thumb" is that about 5% of boiler input capacity can be recovered with a properly sized economizer. A higher percentage can be recovered with a Flue Gas Condenser, assuming there is enough cold water to condense all of the flue gas that is available. Therefore, for 'ball parking' purposes, start by comparing boiler input capacity with the need to heat water.

Introducing Thermal Insulation

From the IR images we can find that heat lost from the corners od the metal doors due to lack of insulation. A typical door 3 X 8 is 36 sq. ft. so 8 of the 4 6 wide MLV will cover it. 9 of the 4X1 foam will be needed. You could use gaskets that are ordinary thermal sealing gasketing foam strips from the hardware store, but far better results can be had if you use our Super Soundproofing 1/8 Thick Self-Adhesive Tape, because it is a closed cell material, will seal better and is much more durable. It is a gray tape in widths of 1/4, 3/8 & 1/2 for door sealing. Apply strips on top of each other to build up and close wide gaps.

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Energy Audit report for Fitness and Recreation center (Gym) Remove the molding from around, the door and check the gap between the frame of the door and the rough framing. Sliding doors have little or no thermal insulation qualities at all and are best replaced. If its a glass patio door, you could cover part of it with a mat and make a holding panel with mat attached to it to cover the door that moves when its shut. Another option is to add another patio door with a new frame. This double door will block a lot of heat escape by trapping air between the door panels. Commercially available thermal proofing sliding glass doors can be had here.

Fig 5.2 shows the fitting of transom seal Fig 5.3 shows the top view of the foam seal fitting. Some notes about our Door Sweep (transom seal): (The part that should seal the door bottom against sound and that fits on the bottom of the door). A transom seal is usually available from the hardware store that fits on the floor across the doorway. Use this kind too, if you have a huge gap. Try to get one with a rubber flap. (Mechanical ones are expensive and will eventually fail). Fig 5.4 shows the front view of the door seals

Fig 5.5 shows the pictures from an IR camera the heat loss from indoor and outdoor doors Department of Mechanical Engg, Purdue University Calumet Page 15

Energy Audit report for Fitness and Recreation center (Gym) The correct type of seal will not only help seal out heat lost but improve the doors thermal rating. A seal is essential to properly thermal proof a door. The seal is a rubber loop, cut to your door width size, modified by us with sealed ends for added performance in creating a dead air space in the loop. Well cut this to an exact fit for the width of your door if youll give us the measurement of the width of the door. You will also receive the proper screws to mount it to your door, depending on whether its metal or wood. Only a screwdriver and a few minutes is needed to install this very much needed attachment to block sound from coming underneath your door.

5.2: Cost and savings analysis Lighting ECO

Replacing an existing 800W Metal halide lamp with a 120W Induction florescent lamp when it burns out Cost: The price remains the same for 50.4 kW and for 47.2 kW Power savings: 50.4 47.2 = 3.2 kW Lamp operates for 5400 hrs. per year and electricity cost is $0.06732 Savings = 3.2 * 5400 * 0.06732 = $1163.32/ year

Type

WATT

Life hrs. 16,000

100,000

lumens

No of bulbs 63 394

Total kW 50.4 47.2

Metal Halide Inducti on floresc ent

800 120

60,000 9600

Cost incl. fixture 295 150

Total ($) 18,585 59,100

Ann. hrs 5,400 5,400

Life Expect ancy 3yrs 19 yrs.

Table 5.2.1 shows the comparison of different lighting systems

Metal doors insulation ECO Since there is no insulation added to the door, use 1/8 MLV with 1/4 closed cell foam ($14.63 per lineal ft.) bonded to it. Then cover with Super Soundproofing acoustical mat. Usually 1 thick will suffice. Cut it a bit oversize to cover the seam of the door at the frame to help seal it. You can use the mat with the adhesive backing if you want to re-use it or remove it later.

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Energy Audit report for Fitness and Recreation center (Gym) Type Transom seal Insulation tape Total Total dim. Required (Ft.) Cost per ft. ($) Total ($) 25 100 45 14.63 1125 1463 2588

Table 5.2.2 shows the comparison of different types of door seals Thermostat ECO

Type Mechanical Programmable

Unit Cost ($) Installation cost ($) Total ($) 45 110 450 475 495 585

Table 5.2.3 shows the comparison of different thermostats Economizer ECO Since there is no economizer installed currently the installation cost for the boiler is estimated. Type Economizer Unit Cost ($) 2850 Installation cost ($) 2000 Total ($) 4850

Table 5.2.4 shows the of cost estimate of economizer

Payback years calculation

Type Lighting Door Insulation Economizer Thermostat Initial cost diff. Operating cost savings Simple payback 30,000 500 2850 90 2900 275 1150 90 10.3 yrs. 1.8 yrs. 2.5 yrs. 1.0 yrs.

Table 5.2.5 shows the payback year calculation of different systems

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Energy Audit report for Fitness and Recreation center (Gym)

5.3: Evaluation of Energy and Procurement Strategies

Energizing Indianas Commercial and Industrial (C&I) Prescriptive Rebate Program is specifically designed to help facility managers and building owners achieve long-term, cost-effective energy savings. A prescriptive rebate structure provides your business or organization with rebates based on the installation of energy efficiency equipment and system improvements. Upgrades can include Lighting, Variable Frequency Drives (VFDs), HVAC, and efficient ENERGY STAR commercial kitchen appliances. Objectives of the C&I Prescriptive Rebate Program are to:

Help C&I facilities lower electric energy consumption Help C&I customers decrease their overall energy costs Encourage vendors and contractors to actively promote and install energy-efficient technologies for their C&I customers

Weve built a network of HVAC, lighting and appliance suppliers and electrical contractors to work with you to meet your energy-saving needs. Lower your energy costs today, and do your part to energize Indiana! Type Lighting Door Insulation Economizer Thermostat Total Estimated kWh. Cost savings ($) 3.2 0.5 0.5 0.1 4.3 1161 182 182 36 1561

Table 5.3.1 shows the cost savings of different systems

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Energy Audit report for Fitness and Recreation center (Gym)

Section 6: Action Plan

6.1 Recommended ECOs and an implementation schedule
The main objective of this energy audit is to identify potential Energy Conservation and Retrofit Measures and to determine whether or not the identified ECRMs are economically feasible to warrant the cost for planning and implementation of each measure. Economic feasibility of each identified measure was evaluated through a simple payback analysis. The simple payback analysis consists of establishing the Engineers Opinion of Probable Construction Cost estimates, O&M estimates, projected annual energy savings estimates, and the potential value of Indiana Clean Energy rebates, or Renewable Energy Credits, if applicable. The simple payback period is then determined as the amount of time (years) until the energy savings associated with each measure amounts to the capital investment cost. Ranking 1 2 3 4 Type Lighting Door Insulation Economizer Thermostat Initial cost diff. Operating cost savings Simple payback 30,000 500 2850 90 2900 275 1150 90 10.3 yrs. 1.8 yrs. 2.5 yrs. 1.0 yrs.

Table 6.1 shows the simple payback years for different systems

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Energy Audit report for Fitness and Recreation center (Gym)

February 2nd February 7th

Audit team visits the gymnasium Energy bill analysis

February 14th Meeting to discuss regarding potential ECOs February 21st Finalize the potential ECOs February 28th Submit the draft copy of the report March 1st March 6th March 8th March 15th March 22nd March 26th March 29th April 2nd April 5th April 9th April 11th April 14th Submit the final copy of the report Evaluation of the report Finalizing of the ECOs Release of funds for implementing ECOs Start of work to implement lighting ECO Start of work to implement door insulation ECO End of work to implement door insulation ECO Start of work to implement Economizer ECO End of work to implement lighting ECO Start of work to implement thermostat ECO End of work to implement thermostat ECO End of work to implement Economizer ECO

Table 5.2.1 shows the schedule for different ECOs and energy audit

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Energy Audit report for Fitness and Recreation center (Gym)

Section 7: Conclusion and post implementation review

Lighting ECO has the highest payback period, but the lifespan of the lighting systems suggested has the longest life span of over 100,000 hrs. and consume less energy to provide the lighting at the same time since the life span is high it will have very low maintenance cost and according to the working hrs. of the gymnasium. As an immediate effect we can suggest to upgrade the lighting systems with the Induction fluorescent, since it saves energy and has a longer life. These lighting systems can be bought online or in store. It might need more hours of workmanship since more bulbs has to be installed. It might take up to a week to complete the work. As a second choice Door insulation can be done easily with in a day since there are less no. of doors that are facing outside, transom seal may take a little more work since it needs to be fixed with screws at the lower bottom end of the doors, but the foam tape do not need much of the work. Installing the economizer will increase the efficiency of the boiler and this might require installing prefabricated heat exchangers and other fittings and it will consume less time near the boiler. Though programmable thermostat as recommended has a lesser cost cutting feature directly but it saves lot of energy indirectly by better temperature management which is directly proportional to cost cutting. It also eliminates the use of compressor which avoids the initial and maintenance cost and also helps reduce the energy consumed by compressor. From the below table we can estimate the savings from different type of ECOs

Type Lighting Door Insulation Economizer Thermostat Total

Estimated kWh. Cost savings ($) 3.2 0.5 0.5 0.1 4.3 1161 182 182 36 1561

Table 7.1 shows the cost savings from different systems

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