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Virginia Department of Corrections

Virginia Corrections Project Reduces Costs While Ensuring Safety

Energy Savings Performance Contracting helped state agency reach goals and win Governor’s award

The Virginia Department of Corrections, like many state agencies, faced a lack of funds to deal with an aging infrastructure and deferred maintenance – along with the added challenge of the governor’s executive order to reduce energy use. The solution, from partner Johnson Controls, allowed them to make more than $51 million in facility infrastructure upgrades with a minimal impact on their capital budget.

Through energy savings performance contracting, the Department of Corrections is able to pay for energy-efficiency facility improvements through the resulting utility savings. Facility improvements are expected to reduce electricity use by more than 17.3 million kWH and water use by more than 244 million gallons over 15 years. In addition to maximizing energy efficiency, the program helps the Department significantly decrease consumption of propane, natural gas and oil, and eliminate CO2 emissions by 11,000 metric tons.

These energy and operational upgrades earned the Virginia Department of Corrections one of the 2011 Governor’s Environmental Excellence Awards.

A Portfolio of Energy Management Technology

First, Johnson Controls conducted facility audits to identify all possible energy conservation measures and met with building and grounds personnel to identify and prioritize their needs in such a sensitive environment. A comprehensive portfolio of energy and facility improvement measures was implemented, with a focus on reducing the Department’s overall energy consumption to help meet state goals.

Second, the focus turned to conservation measures that would generate positive cash flow that could address critical deferred maintenance and remove those costs from the capital budget and state residents’ tax burden.

Improvements included:

  • Lighting retrofits and lighting occupancy sensors
  • Building envelope upgrades
  • Replacement or upgrades of chillers, boilers, rooftop units and other HVAC equipment
  • Hot water heater replacements
  • Steam system repairs
  • Installation of heat pump condensing units and high efficiency motors
  • Domestic water retrofits and fixture upgrades
  • Installation of solar thermal panels
  • Installation of temperature control systems including the Metasys® building management system

The buildings and grounds staff was trained on the new equipment and technologies to ensure efficient operation. Johnson Controls will be responsible for maintenance of installed systems and equipment, and the measurement and verification of energy use, water consumption and resulting savings.

Water Conservation Innovations

Among the most notable upgrades at the Virginia Corrections facilities were water conservation measures that have reduced water usage by more than 90 million gallons per year. Johnson Controls installed water-efficient appliances, fixtures and valves. Low-volume fixtures and valves reduced toilet flow from 3.5 gallons to 1.6 gallons per flush, sink flow from 2.2 to 0.5 gallons per minute, and shower flow from 3.0 to 2.0 gallons per minute.

More innovative measures included electronic controls on toilet and shower valves to limit the number of flushes per hour and the number of minutes per shower. Water use at each facility can now be closely monitored and reported.

Reducing Dependence on Fossil Fuels

Thanks to the portfolio of improvements, the Virginia Department of Corrections is expected to reduce its electric demand by 17,352,598 kWH, propane use by 194,576 gallons, natural gas by 362,075 therms, and coal and oil by 61,886 and 114,717 MMBTUs, respectively, over 15 years. In total, the reduced use of fossil fuels will prevent the release of 11,000 metric tons of CO2 into the atmosphere.

One innovative and cost-effective installation will use solar thermal energy to replace fossil fuels in heating water. With funds from the American Recovery and Reinvestment Act, Johnson Controls is installing more than 300 solar thermal panels at the St. Brides Correctional Facility, which is expected to reduce propane consumption by 25 percent. The panels will produce 45 percent of the hot water used at the facility.

Special Considerations of a Prison Installation

The mission of any Department of Corrections is to enhance public safety by supervising offenders in a humane and cost-effective manner. The Virginia Department of Corrections provides custody, supervision and programs for about 31,000 offenders in 50 institutions across the state.

Safety was a consideration throughout the process, as limited access, strict schedules, and the need to closely monitor tools and equipment brought into correctional facilities was a constant concern. “These factors all impact work time and add challenges to project management. Johnson Controls did very well in coordinating the projects, working with our staff and developing the relationships necessary to keep the work moving in a timely manner with minimal disruption,” says Kimberley Lipp, chief – Architectural and Engineering Services.

The Department was also able to make improvements that will help maintain a calm and safe environment over the long term. “Anytime you improve the physical plant operations, you reduce the potential issues our correctional officers may have to deal with,” says Lipp. Electronic controls that help conserve water can also be used to lockout toilets so they can’t be flushed prior to a contraband search. This feature can also help prevent an inmate’s attempt to flood his cell.

Teaching Self-sufficiency

To help offenders transition from prison to productive participation in the community, Johnson Controls is working with the Virginia Department of Corrections to develop a green HVAC vocational program. A new education facility will be equipped with mechanical HVAC equipment that will be used to train participating inmates for green careers such as HVAC/R Service and Control Technicians and Facility Maintenance Technicians.

Johnson Controls will team with the Department to assess inmate aptitude and develop curriculum and course materials that best suit them. Inmates will have the opportunity to learn how to operate and support the equipment using energy efficient operations and maintenance practices.

Lab development and inmate training are being funded through savings generated by the energy efficiency upgrades made under the Department’s performance contract.

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