HVAC retrofit concerns.

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The heating, ventilating, and air conditioning system is criticalin any building, and is responsible for
up to 40 percent of the totalenergy consumed by a typical commercial building. Proper operation
ofthe system is essential both to energy efficiency and comfort fortenants and/or customers.
Improper operation can lead to unnecessaryenergy consumption, tenant complaints, poor indoor air
quality, and evenenvironmental damage.
Most HVAC systems can be retrofitted to improve reliability, reduce energy consumption, and meet
new environmental standards. The first two concerns are the most common reasons for HVAC
system retrofits, but environmental concerns should be considered as a part of any change.
New developments in control systems, variable-speed drives, and other equipment provide
additional incentives for system retrofits. Changing codes and standards also are factors to be
considered when evaluating a possible HVAC system retrofit.
Reliability
As equipment ages, it has a tendency to break down more frequently. The age at which breakdowns
occur will vary with the type of equipment in the building, but increased maintenance costs and/or
frequency of breakdowns are major clues that the equipment needs to be modernized. Direct
replacement of the equipment is the simplest approach, but may not be the best choice in every
case.
Instead, managers can consider re-fitting parts of an older or inefficient system. For example,
pneumatic temperature-control systems are widely used because of their simplicity but require
continual maintenance and calibration. New, computerized, direct digital control (DDC) systems
provide more precise control and greater reliability, along with better energy efficiency. In addition,
the information capability of these systems can improve the productivity of the maintenance staff, a
side benefit of a retrofit that was designed to save energy.
Energy efficiency
Energy efficiency is the most common reason for retrofitting an HVAC system. One option for the
air-distribution system is to convert dual-duct, multi-zone, or constant volume systems to a variable
volume system. This may require damper installation, duct-work modifications, and fan changes.
The older variable-volume systems can have outlet dampers or inlet guide-vanes replaced with
variable speed drives for improved savings.
The chilled-water system can be converted to a primary/secondary system that uses variable water
flow for the secondary system, which feeds the chilled water coils that allow the system to provide
cooling without utilizing the chiller.
These systems are useful when cooling is required during low ambient temperature conditions. This
can include using a heat exchanger between the chilled-water loop and the condenser system,
a "strainer cycle" that uses a cross-connection (with filtering and treatment) between the chilledwater system and the condenser system, or a refrigerant migration (or "free cooling") cyde within
the chiller.

As noted earlier, control-system changes are among the most popular retrofits. The improved
technology of current DDC systems provides improved control of the system, which can increase
tenant comfort as well as save energy. Most of these systems also can provide the information
required to bill tenants for after-hours energy consumption. Many of the manufacturers provide this
type of equipment, which will provide similar savings in individual or multi-unit applications.
In addition, the DDC system can provide information about the building and the system - a service
that will allow the maintenance staff to check on conditions without going all over the building.
If there is a complaint, the temperature in the area and the operation of the equipment can be
checked immediately. However, consistent monitoring of the equipment is still important to identify
potential problems before they affect tenants.
Environmental concerns
HVAC system retrofits can affect local environmental concerns, principally indoor air quality (IAQ),
as well as global concerns such as ozone depletion and global warming.
Most studies have found that the majority of IAQ problems are related to HVAC systems with
inadequate air flow, poor maintenance, and insufficient outside air flow. When the HVAC system is
identified as the cause of a problem, a system retrofit may be required to solve the problem.
Ozone depletion, one of today's most talked-about globalenvironmental concerns, has been traced in
part to HVAC systems that usechlorofluorocarbon (CFC) or hydrochlorofluorocarbon (HCFC)
refrigerants.While there currently is no requirement to remove or modify thisequipment, increased
costs of these refrigerants and regulations aimedat reducing emissions are encouraging many
managers to consider thesechanges.
Older chillers can be retrofitted to utilize replacement refrigerants that are more ozone friendly.
HCFC-123 is the current choice to replace CFC-11, while HFC-134a (hydrofluorocarbon) is
the current choice to replace CFC-12. HCFC-123 is an interim solution, and is currently scheduled
to be phased out starting in 2010.
There is no compelling reason to retrofit a chiller with a new refrigerant unless major work is to be
done on the unit. On the other hand, it may be more cost effective to replace the equipment if it
is old and near the end of its useful life.
Reciprocating chillers and direct-expansion systems generally utilize HCFC-22, which also is
scheduled to be phased out starting in 2010. Several alternative replacement refrigerants are
currently undergoing testing, but no manufacturer has yet settled on a replacement.
Global warming also is becoming a concern, and agreements may be adopted to reduce carbon
dioxide emissions by reducing the burning of fossil fuels. Refrigerants have a direct global-warming
impact, as well as an indirect impact because of the energy their systems consume. Thus, any
overall system efficiency improvement also will reduce carbon dioxide emissions.
There are several choices for new or replacement chillers. Centrifugal and rotary screw chillers
utilizing HCFC-123 or HCFC-22 are available from several manufacturers.
Another option is to utilize double-effect absorption chillers, either steam or gas-fired. These units
use water and lithium bromide and have no ozone-depletion or global-warming potential. The
double-effect absorbers are much more efficient than the old-fashioned single-effect absorbers.

How to proceed
Before any retrofit work begins, managers must ensure that the system is operating as effectively as
possible. This means that all of the components, including the controls, must perform their
intended function. If this is not done, changes may be made that are not necessary or that may not
produce the expected results.

Testing and balancing of the system should be included as part of any major retrofit project. In
addition, managers should allow time in the engineer's contract to review and participate in the
start-up of the changes. This will help ensure that the system will function as intended.
Because HVAC retrofits can be very complicated, owners and property managers must look to
outside sources for help in designing a retrofit and evaluating its benefits.
One place to start may be a local utility company. Many have programs that evaluate individual
systems and make general suggestions, which can serve as a basis for deciding whether or not to
proceed further. The utility also may have programs to help with the cost of an engineering study of
the system or the cost of the retrofit. They also may be able to provide a list of contractors or
engineers who can offer further advice.
The building's HVAC contractor, who already is familiar with the system, may be able to suggest
possible changes, as well.
The third place to look is a consulting engineer who is familiar with operating systems. However,
the retrofit process must start with a thorough evaluation of the existing system, a service which
many engineers are not equipped to provide. Many large HVAC contractors have engineers on staff
or work with engineers who are familiar with retrofitting systems.
Whatever course is chosen, managers should take care to have in place a comprehensive strategy
for their retrofit. Making changes one at a time without an overall master Plan may cause more
problems than it solves and may defeat the intended purpose of improving the reliability and/or
efficiency of the system. Once the master plan is in place, the actual work may be done in stages, as
funding or time permits.
Conclusion
HVAC retrofits are generally undertaken to boost a system's cost or energy efficiency. Any retrofit
should take both of these factors, as well as environmental concerns, into account. Doing otherwise
would be short-sighted and may not be in the best interests of the building.
Because of the complexity and range of choices in an HVAC retrofit, the owner and/or manager
should look to a contractor or engineer who is experienced in working with and retrofitting existing
systems.
An HVAC-system retrofit generally offers improved energy efficiency and reduced operating costs,
as well as improved tenant comfort and satisfaction. Greater attention to ozone depletion and global
warming may also be used in marketing an "environmentally friendly" building.
Jon R. Haviland, P.E., C.E.M., is president of Criterium-Haviland Engineers, a consulting firm that

provides expertise on mechanical systems, control systems, and energy efficiency for commercial
and industrial facilities. Mr. Haviland has 20 years of experience in facility engineering and
management, including 10 years as director of energy and engineering for the consolidated
facilities group that served the May California and Robinson's department stores in Los Angeles.
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