Retro-Commissioning: Uncovering Hidden Savings in Existing Buildings

If your building operates with older plumbing or heating systems, hidden inefficiencies may be costing you more than you realize. Retro-commissioning offers an opportunity to uncover those inefficiencies and address them, leading to substantial savings in energy and water use.

For example, modern boilers can achieve efficiencies of up to 90%, compared to just 60% for those installed 25 years ago. Upgrading to more efficient systems—such as tankless water heaters or low-flow plumbing fixtures—can lead to significant yearly savings for families and businesses alike.

Below, we’ll explore how retro-commissioning can uncover inefficiencies in older plumbing and heating systems, leading to improved efficiency, lower operational costs and greater comfort for everyone in the building.

Fundamentals of Retro-Commissioning

ENERGY STAR—a program overseen by the US Department of Energy and the Environmental Protection Agency—refers to retro-commissioning as a specific type of commissioning, which is an effort to verify a building’s systems were designed and installed per the facility owner’s operational needs.

In commissioning, your task is to test the system functions and verify that the building’s owner can optimally operate and maintain the structure. Retro-commissioning typically takes place three to five years after the building’s original commissioning and will help the owner determine new ways to improve the facilities.

A retro-commissioning expert will analyze key components of your building’s water and heating systems, such as:

• Boiler efficiency: Is your boiler outdated and consuming too much energy to produce hot water or heat your space?
• Water heater performance: Would a tankless water heater be a better option for your facility’s needs?
• Plumbing fixtures: Could you be saving water and money with low-flow fixtures, such as faucets and showerheads?
• System calibration: Are your existing systems optimized to perform efficiently in their current setup?

Companies needing guidance in retro-commissioning can take advantage of the expertise of a commissioning firm, whose experts should be adept at uncovering hidden savings in existing buildings.

Main Benefits of Retro-Commissioning

Save Energy and Water: During the retro-commissioning process, technicians will identify opportunities to upgrade the systems. For instance, modern boilers can reduce energy consumption by 20-30%, [SS1] while tankless water heaters—which heat water on demand—can cut energy consumption by up to 34% [SS2] for buildings that use less than 41 gallons of hot water daily.

Reduce Operational Costs: An investment in more efficient fixtures can translate into significant operational savings as well. According to the EPA’s WaterSense program, installing water-efficient fixtures—like toilets that use 1.6 gallons per flush (GPF) and low-flow showerheads—can lead to significant water savings [SS3] and lower utility bills over time.

Installing energy-efficient systems—such as LED lights with motion sensors that activate when people are using a room—is another example of how to bring down operational costs. By checking with your utility, you may find that you’ll get a discount when running certain equipment during off-peak hours, if that will work for your production schedule. Retro-commissioning experts will examine all aspects of the system, such as verifying whether the HVAC thermostats are adjusted for daylight saving time.

Enhance Comfort for Occupants and Visitors: One of the top reasons for retro-commissioning is due to complaints from people about airflow or overall comfort. Retro-commissioning can also help alleviate comfort issues related to inconsistent hot water supply or poor heating distribution.

For example, it’s possible that occupancy rates have increased or decreased without the building manager taking these shifting personnel levels into account when setting thermostat temperature controls.

Prolong the Life of Equipment: Inefficiencies tend to arise when there’s been a failure to inspect, monitor and maintain equipment on a regular basis. Part of the retro-commissioning project will be to evaluate current maintenance schedules and to reinforce the owner’s commitment to performing maintenance.

Remain Compliant with Regulations: When staff members are not up to date on all energy efficiency and environmental protection regulations, the building may gradually fall out of compliance. A retro-commissioning project will identify any deficiencies in regulatory compliance so the necessary changes (such as upgrades) can be made.

Increase Property Value: A building that has been upgraded to enhance the performance of its various systems will go up in value and look more attractive to potential buyers when it’s time to put it up for sale.

Steps in the Retro-Commissioning Process

Evaluate your current systems

The first step is to assess the condition of your plumbing fixtures and heating equipment, identifying inefficiencies in water and energy usage. Are your boilers outdated? Do you have water heaters or plumbing fixtures that consume more resources than necessary?

Collect data on water and energy usage

Then, gather data on your building’s water and energy consumption, paying particular attention to hot water use. This will inform which systems need upgrading or recalibrating to boost efficiency.

Devise a strategy

Next, work with a retro-commissioning expert to determine the best course of action, whether it’s upgrading to a high-efficiency boiler, installing a tankless water heater or swapping out old fixtures for WaterSense-certified products.

Implement upgrades

Once you have a clear plan in place, it’s important to prioritize the most impactful improvements. This might include upgrading outdated systems, enhancing heating efficiency or addressing plumbing inefficiencies, depending on your building’s specific needs.

Ongoing monitoring and maintenance

Lastly, after retro-commissioning, it’s crucial to regularly monitor the performance of your systems and adjust as necessary to maintain peak efficiency.

Conclusion

By retro-commissioning your plumbing and hydronic heating systems, you can significantly reduce your energy and water consumption, cut operational costs and create a more comfortable environment for everyone who uses your building. Additionally, upgrades to your plumbing and heating systems will help you remain compliant with water and energy efficiency standards, potentially increasing the value of your property.

Whether the motivation is reducing utility costs, improving occupant comfort or extending the life of your equipment, retro-commissioning offers a proven pathway to uncover hidden savings in your building’s plumbing and heating systems.

Sources

https://www.cornerstonecx.com/

https://www.contractormag.com/contributors-guidelines

https://drive.google.com/file/d/1eklF-Ff2iv0-0oapsTm79NYRXNlQmV_m/view

https://www.energystar.gov/sites/default/files/buildings/tools/EPA_BUM_CH5_RetroComm.pdf