Sain Engineering Associates, Inc. (SEA) was recently featured on the front cover of the ASHRAE Journal, September 2020 Issue for innovative technology and work conducted at the ADTRAN East Tower Chiller Plant in Huntsville, Alabama. All savings in the 640,000 square feet tower were gained from modifications to existing equipment and controls that increased efficiency. Since 2005, the EUI has been reduced by 39%. The ADTRAN East Tower in Huntsville, Ala., used several optimization methods to radically reduce energy use without costly equipment replacements. The project was completed without any capital expenditures; all results were gained strictly from modifications to the existing equipment and controls to increase efficiency. These methods saved over $71,326 annually in energy costs with a simple payback of 1.86 years. SEA is very proud of our team members, Jason Brooks, P.E., Director of Engineering and Eric Mobley, Energy Engineer who took lead on this project. Special thanks to Kelley Whalen, facilities supervisor – energy management, HVAC & Electrical at ADTRAN for his appreciation and collaboration on the project.

ADTRAN is a global electronics manufacturer headquartered in Huntsville, Alabama. At over a million square feet, ADTRAN’s Huntsville campus has a sizable footprint, one further augmented by its numerous locations around the globe. Such a large facility footprint typically translates into a high energy consumption rate and high carbon footprint. In 2012, SEA was hired by ADTRAN to perform an ASHRAE Level 1 Energy Audit and provide subsequent commissioning services. Since that time, the partnership between SEA and ADTRAN has flourished, together identifying and implementing a vast array of energy-saving strategies for the telecommunications company. This deliberate collaboration offers a prime example of how strategic energy management can yield remarkable resource resilience and climate mitigation benefits.   A standout among the many projects performed for ADTRAN is the 2023 Greenhouse Gas and Sustainability Study. This effort provided trend analysis on ADTRAN’s energy use, as well as data-driven insights into the manufacturer’s broader carbon footprint. The scope of work for this project included: A Carbon Footprint Assessment. Establishment of energy goals and decarbonization targets, starting with Scope 1 and 2 emissions controls, as part of ADTRAN’s Decarbonization Roadmap. Evaluation of facility improvement measures, development of projects, followed by implementation and integration of key energy solutions, all while keeping focus on operational success.   SEA further assisted in creating Sustainability, Energy, and Load Shed Dashboards to reflect the resilience outcomes resulting from resource efficiency measures selected and implemented at the ADTRAN Huntsville facility. By the end of 2023, SEA and ADTRAN’s combined efforts resulted in a 50% reduction in energy consumption and a defined plan for decreasing the Huntsville campus’ carbon footprint. These practices have gone on to help shape resilience strategies and carbon neutralization efforts across the ADTRAN global enterprise

For the better part of the last decade, the U.S. Army has deliberately pursued energy resilience and infrastructure sustainability under the auspices of the U.S. Army Operational Energy (OE) Program. U.S. Army Central Command (USARCENT) bases in the Middle East have focused on ways to reduce energy, fuel, and water consumption while exploring opportunities to further innovate infrastructure resilience. Since 2017, Sain Engineering Associates, Inc. (SEA) has been part of USARCENT’s resource efficiency initiatives. Based in Birmingham, AL, SEA specializes in sustainable engineering and energy strategies. As Idaho National Laboratory’s lead collaborator in supporting USARCENT’s Operational Energy Program pilot demonstration projects, SEA and its expeditionary Resource Efficiency Managers (eREMs) have gone above and beyond to help identify, develop, and implement resilience strategies for facilities in Kuwait. Most notable among our successes is the recently implemented Camp Arifjan CRSP Yard microgrid project. The CRSP Yard microgrid has demonstrated remarkable success in its first year of operation, significantly reducing fuel usage and costs by 70%. Over the course of the year, there was a 5,045-gallon savings in diesel use, equating to more than a two-thirds cost reduction, from $25,100 to $7,500. Extrapolating this savings over a 20-year lifespan suggests potential savings of $352,200 in diesel costs alone. Combined with savings from GENSET lease reduction, $25,000 annually, cost avoidance projections are estimated to exceed $850,000 over a 20-year lifespan. Moreover, the microgrid’s integration of renewable energy sources with a generator has resulted in a dramatic decrease in diesel generator use from 100% to only 10%. While optimizing generator loading, this reduction extends the life of the generator and decreases maintenance costs. The optimization has not only reduced carbon emissions but also led to substantial savings, including lease-cost savings and decreased operation and maintenance expenses for the remaining GENSET. Overall, the CRSP Yard microgrid has proven to be cost-effective and environmentally friendly, ensuring a resilient power network for the future. SEA’s eREMs were key to this effort, providing “boots on the ground” energy consultation and supporting INL in the development of the concept design and construction drawings. They subsequently worked with local DPW to identify and secure the site. Our team oversaw the installation done by the local BOS contractor and coordinated with the Host Nation utility provider as well. Currently, we are monitoring the results and assisting in training the BOS personnel on the O&M of the system. A small CONEX houses the scalable microgrid control system, inverters, batteries, and communications in a conditioned space. This on-grid/off-grid system integrates multiple types of solar photovoltaic panels, including fixed carport, flexible roof, and vertical Velcro-mounted applications, with a diesel generator and transformer. All electrical lines are buried below ground. With temperatures in this region ranging from a sweltering 105-115 degrees during the day to 91-102 degrees at night, 6 months out of the year, the system is designed to withstand the temperature extremes and dusty conditions with minimal to no disruptions.

While it’s no secret that commissioning is as essential to building projects operating as successfully as possible, it’s critical to remember that commissioning services can be utilized once the building is already in existence to important ends. Retro-commissioning services like those provided by Sain Engineering Associates, Inc. (SEA) is a process to optimize an existing building’s equipment and systems. It can often resolve problems that occurred during original design or construction or address problems that have developed throughout the building’s life as equipment has aged, or as building usage has changed. Retro-commissioning involves a systematic evaluation of opportunities to improve energy-consuming systems. If your building’s utility costs seem exceptionally or unreasonably high, retro-commissioning can help you to identify why the cost has spiked and put your building on a path to reduced utility costs. Here are a few other instances that may indicate it is time to utilize retro-commissioning services: Building occupant discomfort Unseasonably high utility costs Building controls not tuned Simultaneous heating and cooling When building equipment has never before been commissioned or has not been commissioned within the previous three (3) years HVAC control systems are pneumatic When a building’s use has been modified for a different purpose If these issues are plaguing your building, retro-commissioning is your best line of defense. Retro-commissioning benefits everyone in a building from owners to occupants. Building owners see reduced operating costs from the energy savings and better equipment performance, which can result in an overall increase in net operating income. Meanwhile, building occupants are more comfortable because the resulting adjustments create more consistent temperature control and improved indoor air quality. Additionally, building managers face fewer occupant complaints and are better able to manage day-to-day operations and building systems. In short, retro-commissioning results in a win for all involved. Retro-commissioning can produce significant cost savings in existing buildings. According to Jason Brooks, Senior Energy Engineer at SEA, savings vary depending on the building size, age and location, and the scope of the retro-commissioning process. For example, Brooks and his team worked with Shelton State Community College’s Martin campus to assess why the 20-year-old building’s utility costs had crept to nearly $1 million each year. “Shelton State hired SEA to investigate the facilities’ HVAC system. We implemented iterative programming changes and optimized the way these systems performed through customized energy efficient algorithms,” says Brooks. “By carefully monitoring and tuning, we enhanced performance, while not compromising occupant comfort.” These changes proved to be monumental for the overall utility costs and utility consumption. “Ultimately, they saved $387,000 annually – cutting utility cost by 40% after we implemented the system changes for better efficiency and reduced utility consumption greater than 50%,” notes Brooks. “When we reported these savings back to Shelton State, I quantified the improvements by reminding them just how many more scholarships they might be able to offer with $387,000 each year.” Sain Engineering Associates, Inc. provides retro-commissioning services for existing buildings. As an integral component of a facility’s life-cycle, SEA’s retro-commissioning process ensures that buildings operate as optimally as possible by identifying and resolving any issues that have previously plagued the facility and its occupants. Our strong commissioning expertise is founded on our unique skills and experience in system design, troubleshooting and building forensics, and ongoing facility O&M. This allows our commissioning experts to effectively identify and solve building system problems at each phase of a building’s life-cycle. Our commissioning team believes in offering measurable value for every stakeholder in the project, no matter when our services are enlisted in the process. From Continuous Commissioning® to retro-commissioning and re-commissioning, our commissioning professionals can help navigate the complicated process of designing, constructing, and operating buildings correctly.

Since 2015-16, the Department of Defense (DoD) has prioritized energy conservation and sustainability, aiming for Net Zero energy goals across its installations. Leading this charge, the Department of the Navy, including the Marine Corps (USMC), set ambitious targets, with the Marine Corps Logistics Base (MCLB) Albany in Georgia emerging as a frontrunner in resilience and climate mitigation. Despite challenges posed by the COVID-19 pandemic and fiscal constraints, MCLB Albany achieved a remarkable feat by becoming the first DoD installation to attain Net Zero. To achieve this status, the base met the rigorous energy resilience and climate mitigation standards set by the DoD. This milestone signifies that over the course of 365 days, the base generated as much or more electricity than it consumed, marking a significant stride towards achieving energy resilience and promoting climate mitigation. The project incorporates landfill gas generators and a biomass steam turbine, generating over 12.5 Megawatts of electricity annually, which surpasses the base’s energy needs across seasons. Additional upgrades, such as transformer replacements and lighting enhancements, further bolster energy efficiency, with estimated savings of nearly $4 million annually for the federal government. https://deltawayenergy.com/2018/08/waste-to-energy-how-it-works/ In 2017, SEA joined the MCLB-Albany Net Zero effort at a pivotal juncture, contracted through the Marine Corps Installations Command (MCICOM) GF Energy Support Program, to provide energy engineering support and resource management (RM). As a reliable resource in other ongoing MCLB-Albany energy projects at the time, SEA seamlessly integrated into the Net Zero efforts due to its familiarity with procedures, documentation, and leadership. Having worked with MCLB-Albany for over 10 years, SEA played a crucial role in identifying and addressing underlying concerns that had previously slowed the implementation of MCLB-Albany’s energy generation architecture. Over three years, SEA’s resource management efforts addressed critical technical challenges and significantly improved operational efficiency. This included resolving complex connectivity issues between landfill gas generators and the steam turbine, optimizing energy production levels, and successfully securing permits for electricity transfer agreements with Georgia Power. In 2019, MCLB-Albany received the SECNAV Energy Award for Small Installation, followed by the SECNAV Platinum Energy Award in 2020. SEA’s long-standing presence at the base provided crucial consistency over the course of MCLB-Albany’s energy program evolution. The MCLB-Albany Net Zero program not only ensures substantial cost savings and energy security but also reinforces the base’s capability to maintain critical operations during emergencies. It’s projected to save the federal government nearly $100 million in energy costs over 25 years while benefiting Dougherty County through a methane gas purchase agreement. For more insights into this groundbreaking achievement, watch the MCLB-Albany Net Zero video . U.S. Marine Corps photo by Jennifer Parks/Released 201014-M-OG804-006.JPG

Over a decade ago, the Department of Defense (DoD) recognized its place as the nation’s largest energy user, as well as the need to improve energy efficiency, avoid overtaxing the grid, and shift to renewable energy as a means of offsetting negative environmental effects, while meeting operational and installation needs. The military services began by finding ways to make buildings, infrastructure, and utilities more efficient. Around 2013-14, the DoD adopted the Net Zero concept to reduce consumption by installing renewable energy sources. In 2017, the Department of the Army expanded this goal to include Mission Resilience. In 2010, Fort Hunter Liggett (FHL) near King City, California was chosen by the Assistant Secretary of the Army for Installations, Energy, and Environment as one of the nine pilot installations for the Net Zero Initiative. In 2017, SEA was contracted by FHL to provide Resource Efficiency Management (REM) services. With the focus on resilience, SEA REMs helped FHL conduct a groundbreaking ceremony in 2021, initiating the build of a $21.6 million electrical microgrid. This project aims to make FHL the first Army installation capable of achieving Net Zero for mission-critical operations, ensuring 14 days of energy resilience. This is a crucial step towards energy self-sufficiency across the DoD. A microgrid is a self-contained electrical distribution system that can operate independently from the utility grid. FHL has been preparing for this resilience project for several years. Initial steps included upgrading and burying the medium voltage distribution system in the cantonment area. This set the stage for expanding the solar array at the Equipment Concentration Site and adding photovoltaic generation at the O&M yard. The generated power would be stored in batteries, allowing daytime electricity to be used at night. The entire microgrid system would be managed by an automated Supervisor Control and Data Acquisition (SCADA) system, which can respond to grid changes in as little as 1/30th of a second. The microgrid has successfully helped FHL achieve its Net Zero goals.  Despite being an Army Reserve installation, FHL supports significant activities from the Army, Navy, and Special Warfare Groups essential for training initiatives.  If successful, FHL would serve as a model for other installation resilience efforts within the Department of the Army.  This innovative, fully integrated microgrid system will ultimately provide contingency electric power during power outages and persistent grid instability. Once operational, the system will generate more electricity than FHL can consume annually, achieving the Army and DoD’s electrical Net Zero goal. Although FHL will not fully disconnect from the power grid, it will have the capacity to export excess electricity in summer and import it in winter, balancing out to Net Zero. Despite including battery energy storage in the contract, FHL will generate more electricity during the day than it can use or store. The SCADA system will manage this by curtailing solar array output to avoid overloading the grid. FHL is an ideal pilot site for the Net Zero microgrid project, due to its size and scalability. Over the course of the project, SEA’s REM has identified challenges and improvements to establish best practices for other installations. Larger military bases worldwide can model their resilience efforts on FHL’s pilot work, mitigating risks and accelerating implementation based on lessons learned. The initiation of any microgrid project is the culmination of over a decade of projects, development, and planning. It requires forward-thinking to generate DoD-wide projects at the grassroots level, representing a significant achievement. FHL has developed one of the most advanced energy programs, largely due to exceptional technical and budgetary support from the Army Reserve Installation Management Directorate, Sustainment and Resiliency Division. SEA is honored to participate in this energy program and landmark pilot project, setting the stage for future resilience efforts across the DoD.

ABOUT THE FACILITY: The Rane Culinary Science Center is a transformative complex that provides students of hospitality and culinary sciences with a hands-on learning experience to develop commercial hospitality industry skills within an innovative, cutting-edge facility. With SEA’s expertise in Alabama commissioning services, the center ensures optimal functionality and performance. The multi-use facility includes: Luxury boutique hotel with 10 suites, 16 single-room units, and 6 private residences for long-term leasing Spa and rooftop garden 40-seat teaching restaurant for culinary science instructors 9,000 SQ FT food hall with numerous vendors Operational coffee roaster and food/beverage media studio Distilled spirits center with micro-distillery & tasting room 80-student culinary exhibition lab with atrium-style seating and non-conventional cooking stations, which require very complex systems with sophisticated operability. SCOPE OF WORK: SEA was the commissioning authority, ensuring the facility fulfilled the functional and performance requirements for the building owner and occupants. To reach this goal, the commissioning process established and documented Auburn’s criteria for system functions and performance, and verified compliance with criteria throughout the design, construction, and initial period of operation. Additionally, complete O&M manuals along with training on system operations were provided. SEA, known for its Alabama commissioning services, was involved in all phases of the project for Cx of these systems: Building automation system to include any temperature and humidity monitoring, alarming to specific critical areas (freezers, coolers, etc.) All equipment of heating, ventilating, and air conditioning systems, including kitchen exhaust/makeup systems Scheduled, occupancy sensor, and daylight dimming lighting controls Secondary electrical distribution system Domestic water heating systems and distribution piping Domestic and process water pumping and mixing systems CHALLENGES / IMPACT / RECOGNITION: Delays in construction caused commissioning to occur after occupancy. SEA was able to discreetly execute a successful commissioning process, working around the classroom schedule, kitchens, and distillery labs; and the occupancy schedules of the private luxury suites and spa. Exquisite cleanliness and discretion were paramount to avoid disturbance of the clientele. Additionally, it’s worth noting that the Rane Culinary Science Center is LEED® certified, reflecting its commitment to sustainability and environmental responsibility.

SEA Partners with Largest State Employer, Airbus for Commissioning Services SEA has provided commissioning services to five buildings covering more than 472k square feet, and continues to be a part of the expansion process as new buildings are requested for additional commissioning services. Airbus Americas, Inc. is expanding its production facility for its Commercial Airplanes division in Mobile, Alabama. The site is the major assembly and delivery site for Airbus commercial aircraft in the United States, and is one of the larger employment centers in the state. Recent construction includes two dual-bay support hangars, expansion to the existing delivery center, a canteen, and ancillary buildings to support the final phase operations of Airbus’ Single Aisle series type aircraft. At A Glance 5 Buildings Commissioned to Date 472k Square Feet of Commissioned Space Each project has been executed in a Design-Build process. The hangars and ancillary buildings will meet, at minimum LEED certified standards. The delivery center will meet LEED Silver standards. As the LEED Commissioning Provider (CxP), SEA provided all necessary services in conjunction with the LEED Fundamental Commissioning prerequisite and Enhanced Commissioning credit. This includes: Reviewing the owner’s project requirements Verifying the basis of design Developing and executing the commissioning plan through the design, construction occupancy and operational phases Performing reviews in stride with the design-build phases Evaluating proposed equipment sequences of operation Developing pre-functional checklists in coordination with the project manager and design-build contractor Developing, executing and documenting functional tests of installed equipment Producing and submitting all documentation required for the LEED Fundamental Commissioning prerequisite and Enhanced Commissioning Credit Systems commissioned, include: Building Envelope Heating, Ventilation and Air Conditioning (HVAC) Electrical (Medium, Low Voltage and Lighting) Domestic Service Hot Water (DHW) Download Project Profile

Energy Resilience Planning Fort Knox’s Energy Program Achieves Resilience Toward Independence For 60 years, Fort Knox located in Kentucky was the home of the U.S. Army Armor Center and was used by the Army and Marine Corps to train crews on the American tanks of the day. Today, new facilities have been under construction, including its largest project to date, the new Army Human Resource Center. This $185M, three-story, 880k sq. ft. complex consists of six interconnected buildings sitting on 104 acres. The new center employs 4,300 soldiers and civilians. AT A GLANCE Fort Knox Facts 880k Square Feet 14 Days Off-Grid Achieved 10M Annual Savings 6 Buildings Achieving Resilience  SEA provides the Army with ongoing energy services and REM support at 17 Army and Army Reserve facilities, including Fort Knox. Assisting clients in planning for secure access to energy and water resources is crucial to preserve choices in a rapidly changing world. SEA’s REM assisted the Fort Knox Energy Team in the successful testing of a multi-million dollar backup power system to plan and be prepared for a more self-sustaining, resilient base. The $62 million program allows the total installation to operate off-grid without the help of outside utility providers. The program will save about $10 million a year and can provide necessary water and energy for mission critical facilities for up to 14 days. Fresh off a streak of awards that has put Fort Knox in an envious position across the U.S. Army, officials of the Directorate of Public Works say they have no plans to slow down. With resilience as their focal point, Fort Knox is positioning to take the next few steps necessary for complete and endless energy independence if faced with disaster. Next Steps The Energy Program has divided its efforts into three strategies: electric, gas and water. Water is a more long-range focus even though water consumption has already been reduced by 70% just by fixing leaks. Right now, the team is focused on making electric and gas energies more efficient and effective. Because gas is used to generate the electricity, the overall gas consumption has flattened particularly because of the climate in Kentucky. The focus now is to determine how to buy gas at its cheapest cost and store it onsite to have the ability to eliminate higher costs during intermediate and peak hours of use.  The need to be compliant with the U.S. Army’s directive for energy resilience is no longer a concern for the installation because the Army goal to remain energy independent for up to 14 straight days has been achieved and even exceeded. Instead, they are looking to shape the future of energy resilience throughout the Department of Defense with the help of SEA’s REM. Download Project Profile