P5 - Smart Labs...• Introduction to Smart Labs • Prerequisites for Smart Labs • Lighting • Mechanical System • Determining the Potential for Air Change Reductions • Centralized

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Today’s Agenda

• Welcome and Introductions• Introduction to Smart Labs• Prerequisites for Smart Labs• Lighting• Mechanical System• Determining the Potential for Air Change Reductions• Centralized Demand Controlled Ventilation• ANSI Z9.5 2012• Exhaust Stack Discharge Volume Reduction• Dashboard and Energy Savings• Constant Commissioning and Return on Investment• Conclusion and Wrap-Up• Questions and Answers

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AIHA / ANSI Z9.5 2012 Standard for Laboratory Ventilation Published September 2012

Minimum requirements and best practices

Supports OSHA Chemical Hygiene Plan and Hazard Assessment

Requires lab ventilation management program

Specifications for new and renovated laboratories

Hood design and operation

Laboratory design

Ventilation system design

Commissioning and routine testing

Work practices and training

Preventative maintenance

Green Labs Symposium March 27, 2014

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Laboratory Ventilation Management Plan (LVMP)

“Management shall establish a Laboratory Ventilation Plan (LVMP) to ensure the proper selection, operation, use, and maintenance of laboratory ventilation equipment.”

1. Commissioning to verify proper performance and use2. Description of training programs for proper use, maintenance,

and testing of lab hoods3. Design of Ventilation Systems4. Maintenance procedures for providing and documenting

reliable operation5. Specifications of monitors to continuously verify proper

operation of the lab hoods6. Standard Procedures for routine testing

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UC Irvine Minimum Safe Fume Hood Air Flow Study

• Another opportunity to reduce energy use in labs is by minimizing the exhaust flow through VAV fume hoods when the sash is closed

• Study to balance safety and energy conservation

• Our goal was to determine the minimum safe exhaust flow for VAV hoods in fume hood driven labs

• By Exposure Control Technologies, Inc. and Safelab Corporation


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• Can exhaust flow can be safely reduced below current design flow ?

• The new ANSI Z9.5 Standard recommends basing the minimum fume hood air flow on the internal volume of the fume hood and internal air change per hour (ACH)

• 375 ACH is roughly equivalent to 25 cfm/ft2 and 150 ACH is roughly equivalent to 10 cfm/ft2

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Safety Considerations:• The processes and materials

generated within the hoods• Hood containment and

dilution of hazardous concentrations within the hood

• Potential for increased corrosion

• Effect on air duct transport and stack discharge velocities


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Reduced Fume Hood Air Flow Study Results Table

5ft hood cfm ACH Evaporation Rate limit

Chemicals

Current Design Minimum

250 375 n/a n/a

New Design Minimum

167 250 Less than1.2 lpm

*

Possible New Design

Minimum

133 200 Less than 1.2 lpm

*

*Any chemical with LEL >1%(10,000 ppm or higher)

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Reduced Fume Hood Air Flow Study Results Table

*Any chemical with LEL > 1%(10,000 ppm or higher)

6ft hood cfm ACH Evaporation Rate limit

Chemicals

Current Design

Minimum

313 375 n/a n/a

New Design Minimum


*

Possible New Design

Minimum


*


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Reduced Fume Hood Air Flow StudyEnergy Savings

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Today’s Agenda



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JUST SAY NO TO BYPASS AIRExhaust Stack Discharge Volume Reduction

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Exhaust Stack Discharge Volume Reduction (ESDVR)

What is bypass and how much energy is wasted?

If so much energy is wasted, what can we do about it?

Steps in the wind-tunnel study process

Stack extensions

Other implementation results

Next steps: wind-responsive controls

Participatory exercise


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What is a bypass?

The bypass brings outside air from the roof through the fan to ensure design velocity out the top of the stack regardless of flow through the building, thus creating a constant-volume system out of a variable-volume system and wasting energy.

This is a High‐Plume Discharge Fan. Bypasses are also fitted to systems with other types of fans.

Page 120

Why have a bypass?

• Allows the system to operate safely and maintain a minimum velocity of discharge to ensure that the plume of air rises up sufficiently to avoid re-entrainment to the building or contamination of adjacent buildings.

• Allows constant-speed and volume fans to work with variable-volume flow from the building

• Provides a simple means of controlling static pressure in the exhaust system


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Lab Exhaust Diagram

Peak Wind

Exhaust FanBypass Damper

Plenum

Fume Hood Building Air Intake

Balcony

3500

FPM

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How much energy is wasted?

• If building flow is 25,000 cfm and required flow from the stack to attain 3,500 fpm is 50,000 cfm, the energy wasted is 50%, at a minimum.

• By reducing the flow in the stack one also reduces the pressure drop in the stack and therefore the effect on energy savings is compounded. Reduced area “shooters” or discharge nozzles typically have much greater losses than expected.

• Each situation is specific to the site.


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If so much energy is wasted,what can we do about it?

• Modeling the building in a wind tunnel to determine the minimum exhaust velocity required with a reasonable stack height instead of selecting the shortest stack possible based on a fairly high velocity

• Install variable-speed drives to control system static pressure

• Program control system to run multiple fans in parallel with a goalof 0% bypass

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One can’t just close bypass and turn down exhaust volume.

Re-entrainment at balcony

2000

-250

0 FP

M

What about closing bypass andletting fans “ride the curve”?

Peak Wind

Building air intake


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Increasestack height

2000-2500 FPM

What about raising stack height?

Peak Wind

2000-2500 FPM

Bypass closed

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1. Build model of campus


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1. Build model of campus2. Install model stacks

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1. Build model of campus2. Install model stacks

3. Install air sampling points (“receptors”)


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Flow Visualization Natural Sciences 1

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Flow Visualization Natural Sciences 1


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Stack Extensions

1. Extraordinary savings1. Small costs up front

2. Passive system that has no maintenance costs

3. Reduced fan energy in one case by 78%

2. But what about the “ugliness” factor?

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The Ugliness Non-Factor: Before


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The Ugliness Non-Factor: After

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Will stack extensions impact the campus architecture?

One of the biggest challenges to raising the stack heights is how will this impact the look of the campus.

UCI completed the following visual simulations prior to the construction. These renderings were provided to the Design Review Team.

To date no one on campus has noticed, or provided negative feedback.


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Natural Sciences I - Existing

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Natural Sciences IProposed 4-Foot Extension


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Natural Sciences I - Existing

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Natural Sciences IProposed 4-Foot Extension


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Natural Sciences II - Existing

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Natural Sciences IIProposed 4-Foot Extension


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Natural Sciences II - Existing

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Natural Sciences II – Proposed 4-Foot Extension


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Croul Hall - Existing

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Croul Hall – Proposed 8-Foot Extension


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McGaugh Hall Stack Extensions

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McGaugh Hall Stack Extensions


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Implementation

• Install variable frequency drives (VFD)

• Closed bypass dampers

• No stack extension

• Annual energy savings:

580,000 kWh

Sprague Hall

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Implementation


• Static pressure reset

• 4’ stack extensions


928,000 kWh

Natural Sciences II


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Implementation

• No stack extensions


• Static pressure reset


287,000 kWh

Hewitt Hall

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Install anemometer 2000-2500 FPM

Peak Wind

Can we do better?

2000-2500 FPM

Bypass closed or openIf building flow insufficient to providevelocity needed


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No Wind

Install anemometer

1500-2000 FPM

Can we do better?

Bypass closed until fans at minimum speed, then throttleAs needed to maintain static pressure

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Typical Design Flow

New Wind Tunnel Design Flow

Required For Dispersion

Required by High Air Change Rate

Required by Low Air Change Rate

ESDVR Savings Without Wind SensingESDVR Energy Savings With Wind Sensing

Typical TimelineExit Velocity Requirements


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Break for Lunch

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Today’s Agenda



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• Air change rates (ACR)• Internal air quality (IAQ)• Sash position of each fume hood• Occupancy• Relative humidity• Temperature• Total supply• Total exhaust

CDCV SystemDashboard and Data Trends for Each Zone

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Visualization of lab HVAC use


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Visualization of lab HVAC useto determine what is driving ACH

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• Fume hood usage range• This hood shows usage between 0%

open and 65% open.

• Change in average sash position from the month prior• Red indicates poorer average green indicates improved

average sash management

Monitoring Fume Hood Usage


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Smart Labs are not just controls and sensors.

Smart Labs provide real time feedback as well as monthly reporting data that is actionable.

Return on investment is directly affected by lab practices.

How many hoods are in use right now in your laband how far open are the sashes?

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Total Flow and ACH ProfileSix-Day Period


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Air Change Rates for Room 1200Graphed Over Six Days

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The delta between 6 air changes per hour in previous labs designs and the 4/2 ACHof Gross Hall is yielding ~$58,000 per year in energy savings.

What does energy savings look like?


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Trending occupancy sensors to normalize energy consumption data

0%

20%

40%

60%

80%

100%

Gross Hall Hewitt Hall

58%27%

Percent Occupied by Building (7 days)

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‐

1.00

2.00

3.00

4.00

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6.00

0:15

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1:45

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22:00

22:45

23:30

Watts per Square Foot

Time of Day

Watts / Gross Square Foot

Hewitt Hall

Gross Hall

Building Load Per Square Foot


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AHU + EF + Pumps + Chilled WaterBuilding Square Feet

0

1

2

3

4

5

60:15

0:45

1:15

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Watts per Square foot

Hewitt Hall Gross Hall Gross Total Building Hewitt Hall Total Building

1 Watt /1000 x 8760 hours x $0.105kWh= $0.92 /SqFt

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Previous Best Practice

Space Type Gross

Hall

0.9 watts/sqft Offices

0.49 watts/sqft

1.1 watts/sqft Labs

0.66 watts/sqft

1 watts/sqft Overall Conditioned Space

0.61 watts/sqft

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0:15

1:30

2:45

4:00

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15:15

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17:45

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20:15

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22:45

0:00

Watts Per Square Foot

24 Hour Actual Watts Per SQFT

Hewitt Hall Watts Per Sqft Gross Hall Watts Per Sqft

0

2

4

6

8

10

12

14

16

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20

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kW

24 Hour Demand Curves

Hewitt Hall 2nd Floor Lighting Demand

Gross Hall 2nd Floor Lighting Demand

0.3W/1000 x 8760 x$0.105kWh= $0.2759 /SqFt

Lighting


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Comparing Two Similar Floors

Hewitt Hall – 2nd floor Gross Hall – 2nd floor

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Lab Air Supply and ExhaustHewitt Hall – 2nd floor• 8 Air changes per hour minimum• No set back during unoccupied periods• Zone presence sensors on fume hoods

Gross Hall – 2nd floor• 4 Air changes per hour minimum occupied• 2 Air Changes per hour minimum unoccupied• Zone presence sensors on fume hoods• Centralized Demand Controlled Ventilation

system adjusting ACH for indoor air quality.

Lab 2501 Lab 2200


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Evidence of Where Building’sHVAC Energy Savings are Achieved

• Air change rates are dynamic responding to occupancy, IAQ, sash position, and thermal demands

• Lab 2200 averages 4 air changes per hour

• Air change rates are dependent on sash position and thermal demand.

• Lab 2501 averages 8 air changes per hour Hewitt Hall

Lab 2501

Gross HallLab 2200

Page 170

Lab Air Flow vs. Time• The HVAC savings of 1 CFM/Ft2 at $4‐5 per CFM can reduce

operational significantly.

• A 1 CFM/Ft2 reduction at Hewitt Hall in just the open lab bays would reduce operational cost by $83,250 per year


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Combining all the data:ACH vs. ΔT Operating Regions

ACH

ΔT

14

12

10

8

6

4

2

Sash and IAQ Driven ACH Governed by Plug

and Lighting Load

Optimal Region

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

High Sash and Electrical Loads or SAT too High

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Combining all the data:ACH vs. ΔT Operating Regions

ACH

ΔT

14

12

10

8

6

4

2

Sash and IAQ Driven ACH Governed by Plug

and Lighting Load

High Sash and Electrical Loadsor SAT too High

Optimal Region

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30


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Solutions to ACH vs. ΔT Excursions Sash Management

Poor IAQ / Lab Practices

Over engineering Add spot cooling

Distribute lab load

Provide dedicated exhaust

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Today’s Agenda



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Continuous Commissioning

-- Meaningful analysis and reports-- Actionable information-- Verification of actions taken:

physical and behavioral

CDCV Find failed lab air control

valves

Review of fume hood sash management

Ensure safe lab air quality

Find excessive air flows due to point sources of heat

Submetering Monitoring of fans, pumps,

and lighting control systems

Verification of energy retrofits

Reduce demand charges by modifying operations

BMS

Locate simultaneous heating and cooling

Reset of static pressure to minimum required

Control run times of office areas

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Troubleshooting a CO2 leakWith the CDCV System

• Researcher connects 4 tanks of CO2 to the lab distribution system and within 8 hours they are empty.

• To find the leak the research staff could have spent hours soaping lines and connections and wasting additional gas listening for the leak.


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Suspected location of CO2 leak

Researcher first plotted all rooms for CO2

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The leak was quickly located and repaired!

Researcher Then Plotted the Roomwith the Suspected CO2 Leak


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The Knowledge Center has been used to locate lab equipment placedtoo close or under thermostats.

Discovery of Lab Equipment Driving Thermal Demand

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Return on Investment

Commissioning– Cx, Rx, MBCx is approximately $2 per SqFt– Hewitt Hall MBCx $131,309– Net present value for 10 years (MBCx every 5 years) Hewitt Hall

$113,590

$(100,000.00)

$(50,000.00)

$‐

$50,000.00

$100,000.00

$150,000.00

$200,000.00

$250,000.00

1 2 3 4 5 6 7 8 9 10 11

Cumulative Cash Flow MBCx Project

MBCx Cumulative Cash Flow MBCx Net Savings

MBCx


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$(200,000.00)

$‐

$200,000.00

$400,000.00

$600,000.00

$800,000.00

$1,000,000.00

$1,200,000.00

$1,400,000.00

1 2 3 4 5 6 7 8 9 10 11

Cumulative Cash Flow

Smart CCx Cumulative Cash Flow Smart CCx Net Savings

Submetering and monitoring your lab can be very competitive with the cost of a single commissioning effort.

CDCV ~$3.12 per SqFt

Sub metering $0.20 per SqFt

Hewitt Hall Sub Metering and CDCV $302,888

Net present value for Hewitt Hall continuous commissioning (10 years) $665,903

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Return on InvestmentSmart CCx although a larger initial investment provides for greater long‐term savings as well as strategic analysis, monitoring, and savings that cannot be accomplished with traditional MBCx.

$(200,000.00)

$‐

$200,000.00

$400,000.00

$600,000.00

$800,000.00

$1,000,000.00

$1,200,000.00

$1,400,000.00

1 2 3 4 5 6 7 8 9 10 11

Cumulative Cash Flow MBCx vs. SMART CCx

Smart CCx Cumulative Cash Flow Smart CCx Net Savings MBCx Cumulative Cash Flow MBCx Net Savings


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Results:

Laboratory Building BEFORE Smart Lab Retrofit

Name Type1

EstimatedAverageACH

VAVorCV

More efficient

than code?

Croul Hall P 6.6 VAV ~ 20%

McGaugh Hall B 9.4 CV No

Reines Hall P 11.3 CV No

Natural Sciences 2 P,B 9.1 VAV ~20%

Biological Sciences 3 B 9.0 VAV ~30%

Calit2 E 6.0 VAV ~20%

GillespieNeurosciences

M 6.8 CV ~20%

Sprague Hall M 7.2 VAV ~20%

Hewitt Hall M 8.7 VAV ~20%

Engineering Hall E 8.0 VAV ~30%

Averages 8.2 VAV ~20%

AFTER Smart Lab Retrofit

kWhSavings

ThermSavings

Total Savings

40% 40% 40%

57% 66% 59%

67% 77% 69%

48% 62% 50%

45% 81% 53%

46% 78% 58%

58% 81% 70%

71% 83% 75%

58% 77% 62%

59% 78% 69%

57% 72% 61%

Type: P = Physical Sciences, B = Biological Sciences, E = Engineering, M = Medical Sciences

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• Motor and bearing wear decreased

• N+1 and greater opportunities

• Failed component detection

• Lab oversight – Hood management

– Chemical excursions

Results:


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Today’s Agenda


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Future of Smart Labs at UC Irvine

Research and development of Smart Labs is an ongoing process that will continue to make our labs more energy efficient and safer.


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Lowering System Pressure DropDuct noise attenuators at lower velocity are no longer necessary and when applicable should be removed.

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LED Lighting System• LED lights with integrated smart controls• Precisely control lighting levels• Occupancy, daylighting, and temperature sensors at

each fixture• Real-time energy management and reporting• Real-time monitoring of each fixture and group• Demand response capable


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LED lighting fixtures• Pendant Mount

• 2x2 or 2x4• Can

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LED Lighting System

• Real-time and historic monitoring

• Trend energy use

• Failure notification


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Lab Display UnitsUCI working with the California Institute for Telecommunications and Information Technology is developing a new LDU that displays:

– Ventilation data

– Environmental health and safety hazard and emergency information

– Energy saving tutorials

Page 192

Lab Display Units

Touchscreen

Android-based display

Graphical output of any Bacnet point

Capable of showing • Training videos• Chemical

inventories• Scheduling• Contact

information


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The savings are building blocks and each must be completed to realize the full savings potential!

1. Complete the prerequisites

2. Safe air change rate optimization

3. Efficient lighting

4. Exhaust fan discharge velocity optimization

5. Removal of pressure drops throughout the system

6. Fume hood standby ventilation optimization

7. Final and continuous commissioning

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Today’s Agenda



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QUESTIONS?Wendell Brase Matt Gudorf Marc Gomez David Kang Fred Bockmiller

[email protected] [email protected] [email protected] [email protected] [email protected]


Documents

P5 - Smart Labs...• Introduction to Smart Labs • Prerequisites for Smart Labs • Lighting • Mechanical System • Determining the Potential for Air Change Reductions • Centralized