CHEMISTRY BUILDING RCX
Presenters:
Bob Kilgore
Matthew McReynolds
Brenna Goode
Project History
The Challenge?
PH 1 Starts
PH 2 Ends
FLOOD
Utility & Energy Use
7,945,346 kWh
26% Increase
5,827,190 kWh
Utility & Energy Use
40,956 MMbtu
36,467 MMbtu
11% Decrease
Utility & Energy Use
46,900 MMbtu
196% Increase
15,828 MMbtu
Utility & Energy Use
46,900 MMbtu
26% Difference Due to Excess Flow
37,268 MMbtu
Utility & Energy Use
How Did Chemistry Compare?
PH 1 Starts
Labs21 Benchmark Data
PH 2 Ends
FLOOD
Processes
Fume Hood Testing
Over 250 Hoods Currently Operational
• Verify sash velocities at multiple positions
• Compared to most recent EHS testing reports
• Verify current hood use
Processes
AHU Testing
• Verify actuator extents and mid-point stroke positions
It’s All about building trust
• Verify sensor installation and accuracy
When we can trust the BAS to
give us good data, we utilize the
trends to analyze the systems
for deficiencies and opportunities
This is also the basis for a
Continuous Commissioning
program
Findings
Improve Averaging Sensor Coverage
T
T
T
T
Existing
Recommended
Improvement
• Improves sensing and therefore control (adding
temp sensors)
• Reduces risk of freezing coils
(adding freeze
stats)
It’s pretty cheap insurance!
Findings
AHU Heat Recovery Control
Single point of control for heat recovery creates one satisfied
AHU and three unsatisfied AHUs
Findings
Chilled Water System
Investigation
• AHU Control Sequences
• AHU Coil Capacities
• Pumping Capacity
• Historical Weather Data
Findings
Chilled Water System
• AHU Control Sequences
Reduce Discharge Air Temperature Based on
Return/Exhaust Humidity Level.
52°F
47°F
+3°F
55°F
50°F
Findings
• AHU Coil Capacities
Chilled Water System
Modeling showed Air Handling Units are driven beyond coil
capacity.
Coils sized for 51.6°F (LAT) @ 89°F / 78°F
Program Demands 47°F (LAT) @ 89°F / 78°F
Coil Physically can’t meet DAT requirements
Findings
Chilled Water System
• Pumping Capacity
Building Chilled Water Users
AHU Tag
Quantity
SAHU-1
1
SAHU-2
1
SAHU-3
1
SAHU-4
1
SAHU-5
1
EXISTING AHU (NW)
1
PROCESS HEAT EXCHANGER
1
AHU-1 (Auditorium)
1
FC-1
2
FC-2
5
FC-4
1
FC-5
1
TOTAL FLOW =
PUMP CAPACITY =
CAPACITY SHORTFALL=
Design Flow
gpm
785
530
785
395
535
2050
341
25
1.5
3
4
4.5
5459 GPM
3600 GPM
1859 GPM
Control
Valve Size
8
6
8
6
6
10
6
??
1/2
1/2
1/2
3/4
Model Number
8"-IDP-415-05-L
6"-EDP-340-05-L
8"-IDP-415-05-L
6"-EDP-280-05-L
6"-EDP-340-05-L
10"-JDP
6-EDP-280-05-L
??
1/2"-FDP-4-05-H
1/2"-FDP-4-05-H
1/2"-FDP-4-05-H
3/4"-HDP-6-05-H
Max GPM
5-70 psig
900
590
900
420
590
2200
420
??
2
3
4
6
Actuator With a 150 Weight
PSI Close Off
(lbs)
NEPTRONIC UB9040
575
NEPTRONIC UB8040
240
NEPTRONIC UB9040
575
NEPTRONIC UB8040
240
NEPTRONIC UB8040
240
NEPTRONIC UB9040
1200
NEPTRONIC UB8040
240
??
??
BELIMO LF24-SR
5
BELIMO LF24-SR
5
BELIMO LF24-SR
5
BELIMO LF24-SR
10
Control
Signal
0-10V
0-10V
0-10V
0-10V
0-10V
0-10V
0-10V
??
0-10V
0-10V
0-10V
0-10V
Fail Safe
Action
NC
NC
NC
NC
NO
NC
NC
??
NC
NC
NC
NC
NC
NC
NC
NC
NO
NC
NC
??
NC
NC
NC
NC
Findings
• Historical Weather data
Chilled Water System
Data From University of Iowa Chilled water
Plant PI System
Airflow
CFM
57,067
56,907
56,906
56,874
56,814
56,714
56,598
56,547
56,530
GPM
745
425
745
470
745
460
745
405
745
375
745
335
745
295
745
227
530
127
Flow
Gallons
44,700
25,500
558,750
352,500
2,592,600
1,600,800
6,302,700
3,426,300
12,583,050
6,333,750
16,024,950
7,205,850
20,360,850
8,062,350
20,562,000
6,265,200
14,946,000
3,581,400
CoilModel
ModelInputs
Inputs(ECM-10)
SAHU-1 Coil
EAT
Coil
Target
DB
WB
EWT
LWT Delta T LAT
56.3
11.4
46.5
90.4
73.2
44.9
62.7
17.8
51.5
56.9
11.8
46.5
87.4
74.1
45.1
62.2
17.1
51.5
56.5
11.3
46.5
84.3
73.2
45.2
61.8
16.6
51.5
55.1
10.1
46.5
78.1
70.4
45.0
61.1
16.1
51.5
54.5
9.5
46.5
79.9
69.2
45.0
61.0
16.0
51.5
53.5
8.5
46.5
76.1
67.0
45.0
60.4
15.4
51.5
52.5
7.6
46.5
72.0
64.9
44.9
59.7
14.8
51.5
50.9
6.0
46.5
67.0
61.2
44.9
58.5
13.6
51.5
62.0
56.9
44.8
50.5
5.7
46.5
57.8
13.0
51.5
Coil
LAT
48.1
51.4
48.5
51.4
48.5
51.4
47.8
51.5
47.6
51.5
47.3
51.5
46.9
51.5
46.5
51.5
46.5
51.5
Target
Tons
400.51
341.79
416.87
358.29
400.47
341.89
345.74
287.19
322.61
264.11
284.43
226.02
248.71
190.41
190.73
132.47
129.07
70.83
Coil
Tons
353.13
314.78
365.09
334.12
351.44
318.58
314.75
272.36
295.68
250.39
264.26
215.14
234.59
181.39
185.71
128.47
125.40
68.68
Calc
Mmbtu
5.2
3.0
65.2
41.2
302.7
186.9
735.9
400.1
1,469.2
739.5
1,871.1
841.4
2,377.3
941.4
2,400.8
731.5
1,745.1
418.2
Findings
• Historical Weather data
Findings
AHU-NW Discharge Air Temperature Sensor
• Discharge air sensor was found to be reporting 5°F high.
• Resulting in Cooling Coil being overdriven and Heating
Coil Under driven.
Findings
• Sensor Calibration
Northwest AHU chilled water valve was
consistently at 100% while the discharge air
temperature struggled to maintain set point.
Unit is running at approximately 60%
Unit
is running
at approximately 60%
full design
capacity.
full design capacity.
Recommendations
ECM-11
Fix AHU-NW Discharge Air Temperature Sensor
• Recalibrate DAT sensor to read true value of conditioned
air.
• This measure was implemented during study.
Results
ECM-11
Results
ECM-11
Recommendations
ECM
Number
Energy Conservation Measure (ECM)
Estimated
Implementation
1
Advanced AHU Heat Recovery Control
2
Singe Loop AHU Discharge Air Temperature Control
3
Dynamic Duct Static Pressure Reset
4
Discharge Air Temperature Set Point Reset
5
Dynamic Pump Differential Pressure Reset
6
Teaching Lab Occupancy Air Flow Reset
7
Reduce Minimum Laboratory Ventilation Rate During Occupied Hours
8
Decommission Unused Fume Hoods
9
Re-Balance Over-Exhausted Fume Hoods
10
Decommission Existing AHU Dehumidification Sequences
11
Fix AHU-NW Discharge Air Temp Sensors
12
Reduce Classroom Lab Fume Exhaust Levels During Unoccupied Hours
13
Reduce Minimum Humidification Setpoint
TOTAL
1
Cost
$164,000
$11,000
$57,000
$42,000
$13,000
$96,000
$108,000
$18,000
$24,000
$5,000
$1,000
$131,000
$7,000
$677,000
Estimated
Estimated Annual Utility Savings
Electric
Steam
Chilled
Annual Cost
(kWh)
(MMBtu)
Water
Avoidance
720
402
$21,500
834
601
$28,300
101,535
776
1,115
$48,800
(68,205)
4,169
3,821
$156,100
13,784
$1,200
33,257
487
13
$10,900
83,226
1,880
1,414
$72,300
18,876
609
216
$16,700
45,783
1,381
2,508
$88,600
41,647
2,326
3,346
$124,100
3,711
1,069
$85,800
30,465
435
7
$9,700
853
$13,600
$677,600
Notes:
Estimated Blended Marginal Rates
(Fiscal Year 2013)
1. Cost estimates are based on RS Means data and past project experience, and does not include project soft costs.
2. Savings calculated assume that ECM-10 and ECM-11 have already been completed
3. This measure is intended to identify approximate itemized savings of removing one (1) hood from operation.
4. This measure was implemented during the summer of 2012.
Simple
Payback
Notes
Years
7.6
2
0.4
2
1.2
2
0.3
2
10.8
2
8.8
2
1.5
2
1.1
2,3
0.3
2
0.0
0.0
4
13.5
2
0.5
2
1.0
$
$
$
0.084 /kWh Elec
15.91 /MMBtu Steam
24.98 /MMBtu Chilled Water
User Concerns
• Uncertainty of purpose
• Unrealistic solutions
• Overly burdensome implementation
• Impact on research and instrumentation
• Impact on the instructional mission
Recommendations
7 of 13 ECMs required coordination with building
users and lab equipment:
ECM
Number
Energy Conservation Measure (ECM)
Estimated
Implementation
Cost1
Estimated Annual Utility Savings
Estimated
Chilled
Electric
Steam
Annual Cost
Water
(kWh)
(MMBtu)
Avoidance
(MMBtu)
(68,205)
4,169
3,821
$156,100
Simple
Payback
Years
Notes
4
Discharge Air Temperature Set Point Reset
$42,000
0.3
2
6
Teaching Lab Occupancy Air Flow Reset
$96,000
33,257
487
13
$10,900
8.8
2
7
Reduce Minimum Laboratory Ventilation Rate During Occupied Hours
$108,000
83,226
1,880
1,414
$72,300
1.5
2
8
10
Decommission Unused Fume Hoods
Decommission Existing AHU Dehumidification Sequences
$24,000
$5,000
18,876
41,647
609
2,326
216
3,346
$16,700
$124,100
1.4
0.0
2,3
12
Reduce Classroom Lab Fume Exhaust Levels During Unoccupied Hours
$131,000
30,465
435
$9,700
13.5
2
$7,000
$413,000
-
853
$13,600
$403,400
0.5
1.0
2,4
13
Reduce Minimum Humidification Setpoint
TOTAL
Notes:
1. Cost estimates are based on RS Means data and past project experience, and does not include project soft costs.
2. Savings calculated assume that ECM-10 and ECM-11 have already been completed
3. Costs associated with this measure include both the decommissioning and recommissioning effort of hood identified.
4. This measure is listed on this table because it was identified as part of this study. However it is no longer recommended to be implemented.
7
-
Estimated Blended Marginal Rates
(Fiscal Year 2013)
$
$
$
0.084 /kWh Elec
15.91 /MMBtu Steam
24.98 /MMBtu Chilled Water
ECM-4
Discharge Air Temperature set Point Reset
• reduce the reheat load: reset the AHU Discharge air set
points upward when dehumidification is not necessary
Room
Number
W254
W76
W182
W174
E127A-1
W290A
E236
W338
W344
W444
E303
E309
W436
Space Use Description
Teaching Laboratory
Lab Equipment Room
Lab Analytical Room
Research Lab
Research Lab
Core Collegiate Lab
Classroom Projection Room
Electrical Closet
Lab Computer Server Room
Class Lab Preparation RoomW428
Classroom Laboratory
Research Lab (Dry)
Research Lab (Dry)
Collegiate - Special Procedures
•
Individual spaces identified
•
Majority of concerned spaces currently
have supplemental cooling systems
User Discussion
ECM-6/ECM-12
Teaching Lab Occupancy Air Flow Reset
• Modify Control Sequence to Reduce Ventilation and
hood exhaust Rate Setpoints during Unoccupied
Hours
• Reduce Minimum Room Airflow to 4 ACH and hood
air flow to NFPA minimum
User Discussion
ECM-6/ECM-12
Teaching Lab Occupancy Air Flow Reset
• Minimum Turndown Capabilities of VAV’s
• Temperature
Confirmed
Control
through
Infrastructure
sample of Shop
Drawings
Add Controllers
•• Reviewed
Viable(Nae)
Timeframes
Winter And
Spring Break
• Each Room Program
Individually
Modified
User Discussion
ECM-7
Reduce Minimum Laboratory Ventilation Rate During
Occupied Hours
• Modify Control Sequence to Reduce Ventilation Rate
Setpoints during Occupied Hours in Classroom
Laboratories.
• Reduce Minimum Room Airflow to 6 ACH
User Discussion
ECM-7
Reduce Minimum Laboratory Ventilation Rate During
Occupied Hours
• Minimum Turndown Capabilities of VAV’s
• Temperature Control Infrastructure
User Discussion
ECM-8
Decommission Unused Fume Hoods
• This measure identifies the savings potential of
decommissioning Individual Fume Hoods
Scope Would Include1. Shut off the exhaust VAV Terminal at Each hood
2. Fully close hood and Secure sash
3. Visually Identify Hood as being Decommissioned
and cannot be used
4. Rebalance Room Airflows to maintain pressure
requirements
User Discussion
ECM-8
Decommission Unused Fume Hoods
Five Rooms Identified
E124
W100
W105
W109
W147
User Discussion
ECM-10
Decommission AHU Dehumidification Sequence
• Remove program to reset DAT down based on return air
humidity.
Impact To Building Occupants:
• Building humidity levels may increase from values currently
seen when mechanical cooling is active (chilled water
available). Spaces will remain within standards for thermal
comfort.
User Discussion
Decommission Existing AHU Dehumidification
Sequence
Impact To Building Occupants:
• Building humidity levels may increase from values currently
seen. Spaces will remain within standards for thermal
comfort.
Risks Associated with Implementation:
• Areas requiring specific environmental humidity levels may
need supplemental dedicated dehumidification equipment.
User Discussion
User Discussion
ECM-13
Reduce Humidification Set Point
• Lower humidification set point from 30% to 20% RH
• Based on equipment environmental tolerances, this
measure was not implemented.
Actual Implementation
• Engaged building participants; early and often
• Free-flow of information
• Responded quickly to concerns
• Took time to learn
Questions?
Thank You