Reduce Lab Operating Costs and Energy Use with New HVAC

Reduce Lab Operating Costs and Energy Use with New HVAC Technology Combinations

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University California Irvine

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UHN: MaRS TMDTUHN: MaRS TMDTUHN: MaRS TMDT

Achieve and Maintain Deep Energy Reduction

Introduce low flow lab design paradigmIntroduce a new tool for lab energy analysisExplain Demand Based Control: Achieve savingsIntelligent Agent Analysis: Maintain SavingsAnalyze using DBC* w/ other HVAC technologies

*Demand Based Control

The Lab Energy and DBC Quiz

The Prize….. Bobblehead Gordon

Caution: Care and travel expenses may be $$$

He can be attracted to Casinos

He likes to travel to far away places

He likes good food, but actually no fish

Low Flow/Energy Lab Design: A New Paradigm

A focus on max savingsNot a grab bag of many ideas

– Focus on a few, high impact concepts

The foundation: Airflow reductionAirflow has greatest energy impactCan also reduce lab’s first cost!

Need for a holistic approach to technologiesUse energy models for first cost & energy impact

– Impact of low flow design & combining concepts often non-intuitive

“In God We Trust, All Others Must Provide Data!”

Holistic Strategies for Increased Savings

Individually evaluating systems is suboptimal DBC, chilled beams, hoods & heat recovery all interact

To optimize lab safety, first cost & energy: Combining systems based on analysis of Net benefits Also use a layered or pyramid approach:

• Recover some of heating and cooling energyHR*

• Decouple heat load from ventilation flows

Chilled Beams

• VAV Exit Velocity Flow VAV ExhFan

• Reduce flow requirements

Demand Based Control/ FH Min

• Basic control approaches VAV Lab Control

*Heat Recovery

Energy, First Cost, & Payback Analysis Tool

Lab focused design analysisCustomized lab analysis engineCalculates both energy & 1st costPowerful “What If” tool for design

Reviewed & approved by utilitiesPG&E, S. Cal. Edison, Con EdCalculates Rebate incentives

Validated by Emcor & JCIHolistic broad range tool For many technologies & concepts

– Heat recovery, chilled beams, etc.

Boston Example Analysis Assumptions

Model typical bldg. w/ 125K GSFLab & lab support area: 50K NSFOffice area: 30K NSF

Base dilution ventilation:Conservatively set to 6 ACH

Energy Cost Assumptions:Electric: $0.12/kWh AvgHeating: $1.00/therm

Low to moderate hoods:One 6’ hood/ 667 ft.2 module (75)

Manifolded exhaust fans: 4 fans are staged plus 1 spare

Boston Example Analysis Assumptions

Room Temp setpoint: 74 DegFHVAC System Eff: Cooling:

– Total COP of chilled water plant: 3.3– Eff. Chilled Beam “COP”: 4.0

Heating plant: 75% total eff.

Typical thermal loading used80% of labs at 3 W/ft2 avg day20% of labs at 6 to 9 W/ft2 avg day

No humidification used

6 ACH Baseline Energy Costs For Boston

Skin & solar gains typically small compared to OABase flow rate (including offices): 72.5K cfm day & 63.7K cfm night

Total baseline energy use is $390K/ year


Individually evaluating systems is suboptimal DBC, chilled beams, hoods & heat recovery

To optimize lab safety, first cost & energy: Combining systems appropriately is best Also use a layered or pyramid approach:



Chilled Beams





*Heat Recovery

Achieving Down to 2 ACH Safely in Labs

Goal: Achieve 2 ACH day/night or 3-4 day /2 nightWhat are the drivers of lab airflow that affect this? Hood flows, thermal loads & ACH rates

Hoods Thermal Load

Demand Based Control of ACH

VAV Hoods

ACH / Dilution Requirement

VAV Supply

2 ACH Min

To achieve lab flows down to 2 ACH to reduce energy & 1st

cost, all flow requirements need to be reduced

Min Flow

Min Load

Reducing/Varying the ACH Rate Flow

Demand Based Control (DBC) solution Reduces lab airflow when lab air is “clean” Increases lab flow when pollutants sensed

Studies show lab air clean > 98% time Equal or better safety w/ the Best airflow A fixed min ACH flow is always to high or low When needed flow can be upped to 8-16 ACH

Clean flow setting of 4/2 ACH is typical 4/2 ACH best done as day/night vs. occ/unocc

– Using 3/2 ACH better & more cost effective– Clean flow of 2 ACH (even during day) is best

Demand Based Control (DBC) provides a safe means to achieve 2 ACH

Demand Based Control

ACH Requirement

2 ACH Min

Lab room 101 Lab Room 102 Conference 103

Supply Air Duct

Exhaust Duct

To BMS

Advisor Data Center

Outdoor Air

Air Data Router

Connectivity

Information Management

Server

Vacuum Pump

Room Sampling Port (RS)Duct Probe

Web User Interface

Sensor Suite with

TVOC, CO2, Dewpoint & Particulate

sensors

Duct Probe

Benefits of Multiplexed Sensing InnovationBetter total first cost Single high quality sensor cost for up to 20 locations Single point digital integration

Lower operating costs Drastically reduced calibration cost

– One high quality sensor to calibrate vs. 20 sensors– Sensors accessible & easily swapped out for calibration every 6 mos.– Sensor’ airflow is filtered by a HEPA for longer life & stability

No sensor replacement costs

Continuous M&V process for long term energy savings Web based data analysis facilitates real time commissioning

– System degradation can be easily observed and corrected

Cost effective, accurate bldg. data for ventilation control Effectively a rental approach to sensors

Impact of Dynamic Control on Dilution Rates

1.5 L spill of acetone in 200 sq ft lab room, 1 sq. m spillAfter vaporized, dynamic system hits TLV in 20 vs. 60 minAfter 2 hours dynamic control has dropped level to 2.6 PPM After 2 hours, 6 ACH system is at 302 PPM or 116 times higher!

Dynamic control approach is always less than 6 ACH baseline

15 min. detection time still better than

6 ACH baseline!

Lower initial ACH helps!

Impact of Air Velocity on Actual Yale Spill Results

ASHRAE Handbook Provides Guidance

New 2011 ASHRAE Handbook, Lab chapter 16:Occ/Unocc Control scope is being limited:

– “There should be no entry into the laboratory during unoccupied setback times”

– “…Occupied ventilation rates should be engaged possibly one hour or more in advance of occupancy to properly dilute any contaminants.”

Active/Demand Based Control is recommended:– “Reducing ventilation requirements in laboratories and vivariums

based on real time sensing of contaminants in the room environment offers opportunities for energy conservation.”

– “This approach can potentially reduce lab air change rates down safely to as low as 2 air changes per hour when the lab air is ‘clean’...”

Lab Case Study: Arizona State UniversityASU Biodesign Institute Bldgs A & B Retrofit Retrofit of Labs and Vivarium

LEED® NC Platinum, R&D 2006 Lab of the Year (Bldg. B) Lab DCV pilot in 2007 to look for EE: 65% savings achieved Full building (A&B) retrofitted in 2009: $1 Million saved/year Currently 24 buildings have been retrofitted:

– Office, classroom, library, sciences bldgs, sports arena & others

0 CFM

2,000 CFM

4,000 CFM

6,000 CFM

8,000 CFM

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18,000 CFM

May-17 May-24 May-31 Jun-8 Jun-15 Jun-22 Jun-29 Jul-6 Jul-16 Jul-23 Jul-30 Aug-6 Aug-13 Aug-20 Aug-27 Sep-3 Sep-11

Exhaust CFM Supply CFM

Average Savings: 10,757 CFMIn 11 Zones (~8,000 ft2)

At $5.14/CFM annually= $55,290 annually= $6.91/ft2 annually< 11 month payback!

Old Average Supply: 15,978 CFM

New Average Supply air : 5,221 CFM

June 4, 2007System

Activation

10,7

57 C

FM S

avin

gs

Pilot Study Results

Hewitt Hall: Designed in 2001

Exceeded Title 24 by 23.7%Biomedical researchRe-Commissioned in 20106 ACH fixed minimum76,905 Square Feet

Gross Hall: Designed in 2009

Exceeded Title 24 by 50.3%Biomedical ResearchSubmitted: LEED PlatinumDBC: 4/2 ACH Occ/Unocc94,705 Square Feet

Both buildings similar in layout, function, & use

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CFM/ Sq. Ft.

CFM / Square Foot ComparisonGross Hall vs. Hewitt Hall

Gross CFM/ Sq. Ft.

Hewitt CFM / Sq. Ft.

1.53 CFM/ ft2 average.

0.52 CFM/ ft2 average.

Significant DBC energy savings of ~1 CFM/ft2

Gross Hall HVAC in kW, 28.2

Hewitt Hall HVAC in kW,

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kW Dem

and

1 Week Fan and Pump Electrical Demand

UCI Now Engaged in Retrofitting 10 Bldgs to DBC

Laboratory Building

Before “Smart Lab” Retrofit After “Smart Lab” Retrofit

Estimated Average ACH

VAV or CV kWh Savings Therm

SavingsCroul Hall 6.6 VAV 41% −McGaugh Hall 9.4 CV 47% 66%Reines Hall 11.3 CV 77% 77%Natural Sciences II 9.1 VAV 48% 62%Biological Sciences 3 9.0 VAV 45% 81%CALIT2 6.0 VAV 46% 78%Gillespie Neurosciences 6.8 CV 58% 81%

Sprague Hall 7.2 VAV 71% 83%Hewitt Hall 8.7 VAV 58% 77%Engineering 3 8.0 VAV 59% 78%

AVERAGES 8.2 − 55% 76%

Aircuity is the largest contributor (>50 to 75%) of savings!

Other Projects Using Demand Based Lab ControlAcadia UniversityArizona State UniversityBeth Israel Medical CenterChicago Botanic Garden Cal State Univ., Monterey Cal TechCase Western Reserve Univ.Colorado Sch. Of MinesChildren’s Hospital of Phil.Dalhousie Univ.Dartmouth CollegeEli LillyFerris State UniversityFood & Drug Admin. (FDA)Ferris State UniversityGrand Valley State UnivHarvard (HSPH)Indiana/Purdue Fort Wayne

LabCorp – BioRepositoryMasdar Institute (MIST)Michigan State UniversityMidwestern UniversityMinistère de l’agriculture, Montreal Heart instituteNevada Cancer InstituteOhio State UniversityOklahoma State UniversityRice UniversitySUNY Stony BrookTexas Children’s HospitalUniversity of Cal IrvineUniversity of IowaUniversity of LouisvilleUniversity of Pennsylvania Univ. Health Network: MaRSVan Andel Institute

Univ. of Louisville: Bio Med 3

UPENN:Carolyn Lynch Lab

UPenn: FisherUPenn: “Demand Based Control is our #1 campus ECM”

DBC Energy Savings of 4 Day/2 Night ACH vs. 6 ACH

Demand Based Control reduces lab HVAC energy by $200K or by 51% vs. 6 ACH. Payback is 2.2 years.

First Cost Saving at Univ. of Houston

Health & Biomedical Sciences Center / Optometry 6 Floors, ~150K sq. ft, 71 labs, 37 vivariums & 24 non-lab zones

Lab & Vivarium flows reduced: Labs from 12 ACH to 4 ACH Vivariums from 15 ACH to 9 ACH

Installed cost : ~ $500KEst. energy savings ~ $250K/ yr2.0 year payback: energy onlyFirst cost savings up to $1.0M!

Demand Based Control helped bring project into budget

HVAC 1st Cost Savings of 4/2 ACH vs. 6 ACH

DBC at 4/2 ACH vs. 6 ACH reduces peak HVAC airflow by 13% or ~ $280K. Net payback is: 10.9 months!

Real Time Intelligent Agent Building Analysis:

Maintaining the Savings

Maintain Savings by Turning Data into Information

What are Intelligent Agent Systems? Typically involves streaming building data to a website Intelligent agent software analyzes the data in real time

What can these systems do? Identify system anomalies and report back to operatorsAnalyze and help optimize system performance

How do these systems report issues? Summary Reports: Performance analysis vs. just real time dataDashboards – Graphically analyze ventilation, IEQ, etc.

Intelligent Agent Analysis Can Answer Many Questions

SUSTAINABILITYSUSTAINABILITY

FACILITIESFACILITIES

HEALTH & SAFETYHEALTH & SAFETY

BUILDING OWNERBUILDING OWNER

Am I saving the Am I saving the energy I

expected to?If not, why?

Is the ventilation system

performing as intended?If not, why?

Are the occupants

safe? Are lab protocols being

followed?

Are my buildings operating at

peak efficiency?What issues require my attention?

Immediate Insight: Am I Saving Energy / Money?

If Not, Why Not?

Supply Reduction Dashblock

• Summarize Flow across some or all areas•Shows Estimated vs. Target Savings•Shows Annual Dollar Value of CFM

This customer is only gettingAbout 50% of their target savings

Total Supply Dashblock•Shows Average Total Flow by Room

This customer has two roomswith much higher flows…

Ventilation Demand analytic can provides answers…

What is driving ACH?

Fume Hood DemandThermal DemandDCV OverrideAt Design Minimum

Are Operators Leaving Sashes Open?

Poor sash managementHood sashes are left open

Analyzes data over month, week, day, etc. ‐ not a snapshot

Range of sash positions is indicated

as well as whether average has increasedor decreased over the

prior period

Could it be a Thermal Issue?

Excess thermal demandApparatus placed near sensor

Another Question: Is Everything Operating Safely?

Detect and track IEQ events with peak or averages

MOS TVOC Sensor PID TVOC Sensor

0.3 to 2.5 µ Particle Counter

Potential Causes of Poor IEQ?

Poor lab practicesWork conducted outside hoodsChemical storage practices Improper equipment venting

Equipment issuesAir Handler or filter issues

Environmental issuesOutside pollutants re‐entrained

Holistic Strategies for Combining





Chilled Beams





*Heat Recovery

Variable Exhaust Fan Exit Velocity Control Innovation

Exhaust fans typically run at constant flow Roof air bypass damper used to maintain CV

To save energy, multiple fans are staged on/offBetter approach: variable speed controlFan flow varied based on building loadUse plenum IEQ monitoring to control exhaust fans

– Demand Control applied to Exhaust Fans for safety

Even staged exhaust fans often consume >2X the energy of VAV

Exhaust Plenum Monitoring: Medical Research Bldg.

1 Hr Event

Comparison of Fan Control Energy vs. 6 ACH

For VAV control of exhaust fans vs. staged fans: Total reduction of $22K or 6% for total reduction of 57%

86K

50K 28K

Layered Holistic Strategies for Increased Savings

Individually evaluating systems is suboptimalDBC, chilled beams, hoods & heat recovery

To optimize lab safety, first cost & energy: Combining appropriate HVAC technologies best

• Recover some of heating and cooling energyHR


Chilled Beams





Demand Based Control (DBC) Improves Beam UseChilled beams at 6 or 8 ACH min:Large overcooling & reheat

Beams at 2- 4 ACH using DBC Greatly cut & eliminate these losses

HVAC system can be downsizedThermal load decoupled from airflowAir system can be resized to 2-4 ACH

The whole of Demand Based Control & Chilled Beams is greater than sum of these parts.

4/2 Project: DBC & Chilled Beams at Cal Poly

Cal Poly Center for Science & Mathematics 198,000 GSF, Budget $88 Million

– “Do the most sustainable project, but only if it doesn’t cost more money”

Architect: ZGF Architects LLP– MEP Engineer: Integral Group / Rumsey Eng.

All lab ventilation air passes through chilled beam Day rate: 4 ACH: full beam cooling Night rate: 2 ACH: less cooling needed Purge rate: 8 ACH

Cal Poly Center First Cost Savings:

Option Standard VAV Reheat

DBC with Chilled Beam

AHU ($7.5/CFM) 250,000 CFM 167,000 CFM

EF ($1.75/CFM) 324,000 CFM 256,000 CFM

Ductwork Standard Reduced 30%

Diffusers Standard Chilled Beam

Piping Reheat Loop Heat Loop, Cooling loop

Overall for 198K GSF Bldg

$716,000 First Cost Reduction (based on SD cost estimating exercise)

DBC & chilled beams were added in value engineering!

Chilled Beam Savings w/ DBC 4/2 ACH vs. 6 ACH

For chilled beam w/ DBC: $15K or 4% reduction.Airflow reduction is ~18% day & ~17% at night

“Right Sizing” Capital Cost Reductions @ 6 ACH

At 6 ACH baseline, gross capital savings of $393K.Chilled Beam (CB) creates net savings of $113K.

DBC payback drops to 5.3 months




• Recover some of heating and cooling energyHR


Chilled Beams

• Low DP Design & VAV Exit Velocity Flow

Low DP & VAV Exh Fan




55% Glycol Runaround Savings at 6 ACH

55% Runaround HR w/ 4/2 DBC: only $24K or 5% saving. HR payback: 9 yrs. even w/ HVAC capital savings

$24K

75% Enthalpy Wheel Savings w/ 4/2 DBC

Enthalpy HR w/ 4/2 DBC (room exhaust only): Only $39K or 8% savings. HR payback: 3.4yrs. due to capital savings

$39K

Saving Lab Energy Presentation Summary

Airflow reduction is the best savings approachEnergy savings can be reduced by 40 to 70%Capital cost savings can be achieved as well

DBC makes chilled beams more effective2- 4 ACH cuts reheat & shares cooling w/ beams

Intelligent agents can prevent loss of savings For a copy of the presentation, contact:

Gordon Sharp, [email protected]?

Quiz Questions:

1. Which of the following would be the best application for Demand Based Control:

A. 10 VAV hoods in a 1000 sq. ft. labB. 10 VAV Hoods in a 600 sq. ft. labC. 10 CV Hoods in a 600 sq. ft labD. 2 VAV hood in a 600 sq. ft. lab


A. Minus 80 Freezer room with VAV air coolingB. Minus 80 Freezer room with chilled beam coolingC. Minus 20 Freezer room with VAV air coolingD. All of the above

Quiz Questions:

3. What DBC purge rate is best for chilled beams:A. 6 ACHB. 8 ACHC. 12 ACHD. 15 ACH

4. How does multiplexed sensing eliminate sensor drift :

A. All sensors are factory calibrated every 6 monthsB. Air is HEPA filtered before it goes through sensorsC. Differential measurements done with same sensorD. All of the above

Quiz Questions:

5. DBC can be used to vary exhaust fan flow by:A. By sensing pollutants in all lab roomsB. By sensing pollutants in all fume hoodsC. By sensing pollutants in the exhaust fan plenumD. All of the above

6. Tiebreaker question:When did Aircuity start its business (Month, Day, & Year)?

Quiz Answers:


A. 10 VAV hoods in a 1000 sq. ft. labB. 10 VAV Hoods in a 600 sq. ft. labC. 10 CV Hoods in a 600 sq. ft labD. 2 VAV hood in a 600 sq. ft. lab


A. Minus 80 Freezer room with VAV air coolingB. Minus 80 Freezer room with chilled beam coolingC. Minus 20 Freezer room with VAV air coolingD. All of the above

Quiz Answers:

3. What DBC purge rate is best for chilled beams:A. 6 ACHB. 8 ACHC. 12 ACHD. 15 ACH

4. How does multiplexed sensing eliminate sensor drift :

A. All sensors are factory calibrated every 6 monthsB. Air is HEPA filtered before it goes through sensorsC. Differential measurements done with same sensorD. All of the above

Quiz Answers:

5. DBC can be used to vary exhaust fan flow by:A. By sensing pollutants in all lab roomsB. By sensing pollutants in all fume hoodsC. By sensing pollutants in the exhaust fan plenumD. All of the above

6. Tiebreaker question: When did Aircuity start its business?

January 7, 2000

Documents

Reduce Lab Operating Costs and Energy Use with New HVAC