Temperature Controls“Why Don’t They Work?

Harry Demetrulias

1. Many Controls Contractors ARE Crooks!

2. Mechanical Design Problems

3. Mechanical Installation Problems and

Equipment Malfunction

4. Operator Errors and Overrides

5. Controls Installations: Misapplied Field

Devices, Sensor Locations, Lack of

Calibration, and PID Loop Tuning

Top 5 Reasons

Control Systems

Don’t Work

Blame the OwnersBlame the Owners

““Owners are too demanding and Owners are too demanding and

unrealistic in their cost expectationsunrealistic in their cost expectations””

Lower!Lower!

How How

Low?Low?

Blame The Blame The

ArchitectsArchitects

““Architects are too Architects are too

focused on aesthetics, focused on aesthetics,

and do not allow and do not allow

adequate space for adequate space for

building systems: building systems:

Mechanical Rooms and Mechanical Rooms and

Interstitial SpaceInterstitial Space””

Blame the GeneralsBlame the Generals

General Contractors punch out projects General Contractors punch out projects

without scheduling adequate time for without scheduling adequate time for

StartStart--up, Checkout, Test & Balance, and up, Checkout, Test & Balance, and

Commissioning activitiesCommissioning activities

““Mechanical Mechanical

Engineers Engineers

Overworked Overworked

and and

Underpaid!Underpaid!””

Blame the Blame the

EngineersEngineers

Blame the SuppliersBlame the Suppliers

““Equipment Suppliers Equipment Suppliers

Just Just

SELL STUFF SELL STUFF

and Donand Don’’t Support it!t Support it!””

Blame the BalancerBlame the Balancer

““Do you really trust Do you really trust

those Test & Balance those Test & Balance

Reports?Reports?””

““Should we blame those Should we blame those

Design/Build Mechanical Design/Build Mechanical

Contractors?Contractors?

Requires Professional

COLLABORATION

FingerFinger--pointing pointing

is easyis easy

Working toward Working toward

SolutionsSolutions

Function or Function or

Malfunction is Malfunction is

without exception without exception

a collaborative a collaborative

effort between effort between

Consultant, Consultant,

Mechanical Mechanical

Contractor, Contractor,

Controls Controls

Contractor and Contractor and

Facility Facility

Operations.Operations.

Temperature Control is simple.

Building Automation is complex…

How can we promote How can we promote

Collaboration?Collaboration?

Delivering Truly Integrated Building Systems To Owners

Requires Collaboration

- Engineers - Controls Contractors - Mechanical Contractors

- Equipment Suppliers - Facility Operations

When Temperature Control When Temperature Control

Becomes ComplicatedBecomes Complicated

•• Economizer ModeEconomizer Mode

•• Variable Volume/FlowVariable Volume/Flow

•• Dynamic ResetsDynamic Resets

•• WarmWarm--up/Coolup/Cool--down Modesdown Modes

•• Building Pressurization ControlBuilding Pressurization Control

•• Smoke Control Smoke Control

••UnderfloorUnderfloor SystemsSystems

•• IAQIAQ

•• Load Shedding Programs Load Shedding Programs

••TOD SchedulingTOD Scheduling

•• PRAC SelfPRAC Self--TuningTuning

•• Integrations to 3Integrations to 3rdrd PartiesParties

•• Validated SystemsValidated Systems

Controls ContractorControls Contractor’’s s

Perspective: Perspective:

The Consultant as The Consultant as

PROBLEMPROBLEM……or or

SolutionSolution

Market Pressure

& the Design Community

• Hyper-competition

• Below Market Design Fees

• Allotted Billable hours for

quality designs and

specifications

• Lack of onsite Project

Engineering

• Reliance on draftsmen to

incorporate last minute

changes

• Addenda Ad Infinitum

The Key:Publish Quality

Documents

⌫ Installation is only as good as the design

⌫ Errors on P&S result in problems in the field

⌫ Malfunction begins in the mind of the designer

⌫ Unedited Master Specifications ⌫ Lower engineering

cost but…

⌫ Many Change Orders/retrofit corrections

• “DDC controllers shall be BACnet. Lonmark AND N2

Open Protocol compliant…”

• “Acceptable manufacturers are Alerton, Andover, Delta,

Honeywell, Invensys, Johnson Controls, Siemens,

Staefa Controls, Trane, or approved equal.”

Example #1: Nonspecific Specifications

Example #2:

Healthcare project…

LOWEST TOTAL COST OF OWNERSHIP

2. Electric, Electronic, and DDC Systems:

a. Alerton Technologies, Inc.

b. Andover Controls Corp.

c. Automated Logic Corporation.

d. Auto-Matrix, Inc.; Auto-Flow Division.

e. CSI Control Systems International, Inc.

f. Danfoss Automatic Controls.

g. Delta Controls Inc.

h. EDA Controls Corp.

i. Electronic Systems USA, Inc.

j. G C Controls, Inc.

k. Honeywell, Inc.; Home & Building Control.

I. Impact Energy Controls Corp

m. Johnson Controls, Inc.; Controls Group.

n. KMC Controls/Kreuter Manufacturing Company.

o. Landis & Staefa, Inc.

p. Luwa Bahnson Inc.

q. McQuay Intemational.

r. Neles-Jamesbury.

s. Pneuline Controls Co.; National Energy Controls Corp.

t. Scientific-Atlanta, Inc.; Control Systems Div.

u. Siebe Environmental Controls; Barber-Coleman/Robertshaw

Products

v. Solidyne Corp.

w. TCS/BASYS Controls

x. Teletrol Systems Inc.

y. Trane Co. (The); North American Commercial Group.

z. Triangle MicroSystems, Inc.

aa. Uni-Line North America; Robertshaw Division.

3. Systems must interface seamlessly with existing front end control

system

Anyone Anyone

Missing?Missing?

7

N C

DPR-O

N O

N C

EA

OA

RA

RA-T

RA-H

MA-T

SA

RA-SD

(Div. 16)

SUPPLY

RETURN

N O

CLG-O

C

C

PFILT-A

Set @ 1"

H LLT-ALM

(38 Deg F)

SA-P

H L

SA-THUM-HL

FFILT-A

Set @ 1"

H L

HSP2-A

Set @4"

H L

SA-SD

(Div. 16)3

4

4

10-27

HUM-O

VSD

RA-F1

VSD

RA-F2

N C

RF1ISO-S

N C

RF2ISO-S

N C

SF1ISO-S

N C

SF2ISO-S

VSD

SF-F1

VSD

SF-F2

N C

HUM-VLV

STM

8

10

9

HSP1-A

Set @4"

H L

0-7.5"

Damper Control: Damper Control: When the unit is commanded on, the When the unit is commanded on, the

outside air damper shall fully open. When the unit is outside air damper shall fully open. When the unit is

commanded off, the outside air damper shall close. The commanded off, the outside air damper shall close. The

exhaust damper shall remain closed and the mixed air exhaust damper shall remain closed and the mixed air

damper shall remain open.damper shall remain open.

Discharge Air Temperature Control:Discharge Air Temperature Control: When the unit is When the unit is

commanded on, the outside air damper, return air damper, and commanded on, the outside air damper, return air damper, and

relief air damper will be open. Discharge temperature sensor SArelief air damper will be open. Discharge temperature sensor SA--

T through the DDC Controller will modulate the cooling coil 2T through the DDC Controller will modulate the cooling coil 2--way way

control valve CLGcontrol valve CLG--O to maintain setting. The discharge air O to maintain setting. The discharge air

temperature will be controlled to maintain a 55temperature will be controlled to maintain a 55°°F F setpointsetpoint..

Example #3:Example #3:

Specify SPECIFICS…

LOWEST TOTAL COST OF OWNERSHIP

Specify limited qualified

bidders that are suitable for

• market type

• product application

• contractor expertise

Balance First Cost with Operating CostBalance First Cost with Operating Cost

⌫ Write Specifications that refer to other sections and technologies.

⌫ Detail the responsibilities

⌫ Furnished by…

⌫ Installed by…

⌫ Wired by…

IT NETWORK

VIDEO-ON-

DEMAND

HOTEL OPERATING

SYSTEM

PABX

PAGING

CMMS

15 BUILDING SERVICES

CCTV SECURITY

CENTRAL PLANT

LIGHTING

ELEVATOR

FIRE

BAS Cross-Referencing

Include at Minimum: Include at Minimum:

Flow DiagramsFlow Diagrams

Point Charts Point Charts

SequencesSequences

Sequence of OperationSequence of Operation

EXHAUST SYSTEM: EFEXHAUST SYSTEM: EF--1 and EF1 and EF--22

Isolation Exhaust Fans EFIsolation Exhaust Fans EF--1 and EF1 and EF--2:2:

On command from the BAS, the fans shall start. If On command from the BAS, the fans shall start. If

for any reason the fan status does not match its for any reason the fan status does not match its

commanded value, an alarm will be generated.commanded value, an alarm will be generated.

ISOLATION ROOM MONITORSISOLATION ROOM MONITORS

System Description:System Description:

The Isolation Rooms shall be monitored by a Space The Isolation Rooms shall be monitored by a Space

Pressure Monitor as described in controls Pressure Monitor as described in controls

specification at minimum and shall generate an specification at minimum and shall generate an

alarm at the BAS upon general alarm or deviation alarm at the BAS upon general alarm or deviation

from space pressurization from space pressurization setpointsetpoint ((adjadj). ).

P.E. Professional

Enforcer⌫ Enforce your

specifications

⌫ Guard against cheating in hyper-competitive market

⌫ Get involved in checkout, functional testing and commissioning

⌫ Specify Commissioning Expectations

⌫ Review Checkout Sheets

⌫ Verify that field devices match the specification

10. Delete lab VAV: Constant volume labs

9. Delete DDC from FCUs

8. Delete SAT Sensors on VAV w/RH

7. Delete DPs across filter racks

6. Delete interfaces to Chillers, Boilers and VFDs

5. Delete AFMS from AHUs SA/RA/OA

4. Delete VAV zones and combine multiple zones

3. Delete Custom Controls on RTUs in lieu of

packaged

2. Delete RH Coils in lieu of Cooling Only VAV

1. Delete DDC from VAV/CAV terminals

Resist DeResist De--Value EngineeringValue Engineering

Technology

⌫ Technology is more affordable than ever.

⌫ But it has made building controls more complicated for Specifying Engineers

Capabilities of Technology

Cost of Technology

19901990 20062006

Get Help from Your

Local Controls Experts

and Sales Engineers

The System Selection Tool was

designed to help specifying engineers

quickly develop detailed, accurate

plans and specifications for heating,

ventilation and air conditioning (HVAC)

Summary: A New

Level of

Engineering Value

⌫ Step 1 Publish Quality Documents

⌫ Step 2 Resist De-Value Engineering

⌫ Step 3 List Qualified Bidders

⌫ Step 4 Enforce Specifications

⌫ Step 5 Get Support and Consultation from Reputable Controls Companies

$

Design/Build and Value Engineering

Exploiting Owner’s Lowest First Cost Demands?

Less quality in More value out

Less quality in More value out

Hyper/Competitive Market and the D/B Model:Contractors Control Design

- Reliance on Equipment Suppliers for TC- Packaged systems w/canned programs

“We can do it

cheaper and

faster!”

Hard Bid/Design/Build

Can this building be fixed?

Slam it in Commission it later

Problem: Mechanical Design & Controls Issues

– Building Pressurization Problems

– Toggling RTU Modes

– Uneven Underfloor Distribution

– Overly cool interior zones

– Overly warm exterior zones

– No humidity control

– Energy Hog—could not qualify for Energy

Star rating

Symptoms

Building # 1

D/B Debacle

ASHRAE Temperature Controls: Temperature Controls: Temperature Controls: Temperature Controls: ““““Why DonWhy DonWhy DonWhy Don’’’’t They Work?t They Work?t They Work?t They Work?””””

Problem: Mechanical Design & Controls Issues

– VAV w/General Exhaust System

– No trunks to distribute UFS

– Improperly placed pressure sensing devices

– No calibrated primary T/H devices

– Cooling mode problems

– Dueling PID Loop Control on RTU

– Inability to alter or augment canned RTU

program—limitations

ASHRAE

Causes

Building # 1

D/B Debacle

Temperature Controls: Temperature Controls: Temperature Controls: Temperature Controls: ““““Why DonWhy DonWhy DonWhy Don’’’’t They Work?t They Work?t They Work?t They Work?””””

Problem: Mechanical Design & Controls Issues

– Hire a COMMISSIONING AGENT!

– Add return fans

– Add trunks to distribute UFS

– Relocate pressure sensing devices

– Calibrate primary T/H devices

– Replace misapplied DDC hardware

– Reprogram and recommission

– Work with commissioning agent

ASHRAE

Solutions

Building # 1

D/B Debacle

Temperature Controls: Temperature Controls: Temperature Controls: Temperature Controls: ““““Why DonWhy DonWhy DonWhy Don’’’’t They Work?t They Work?t They Work?t They Work?””””

⌫ Manual Control

⌫ Automation does not work well in the “HAND”position

““ItIt’’s always a s always a

Controls Controls

Problem!Problem!””

……often times it isoften times it is……

The Controls Contractor as Part of the The Controls Contractor as Part of the

SolutionSolution……

Absorption

Pumping & VFDs

Generators

Lighting

Fire Alarm

Boilers

Fume Hood

Chiller

Power

Fan Systems

Surgical Suites

⌫ Today’s Technology is less expensive

⌫ But the Labor is not

⌫ Margin Expectations Continue to Rise

⌫ Competition is driving the quality out

Controls Industry Controls Industry

as the Problem:as the Problem:

⌫ Person at Metasys workstation

⌫ Today’s Technicians often know computers but lack understanding of basic mechanical systems

⌫ Application Engineering & Commissioning Challenges

⌫ Decreased skill sets in controls software engineering

⌫ Protocols do NOT control buildings

⌫ Software illiteracy

⌫ Reliance on automated processes

⌫ Lack of Quality Management processes

⌫ What is Commissioning?

Building Technology Has Complicated Simple Temperature

Controls

⌫ Comfort

⌫ Lighting

⌫ Security

⌫ Scheduling

⌫ Access control

⌫ Fire safety⌫ Communications

⌫ Fuel conservation

⌫ Power load management

⌫ Maintenance management

COMPLEXITY

Value AddedServices?

⌫ Phase 1 Low First cost

⌫ Phase 2 Prices just went up!

⌫ Phase 3 Delivering less value over time

Controls Industry Controls Industry

as the Problem:as the Problem:

Solution 1:

Can we consider a new

Level of Value?

⌫ Phase 1 Low First cost

⌫ Phase 2 Open Book Pricing

⌫ Phase 3 Pricing Agreements

⌫ Phase 4 Meet the Specifications

⌫ Phase 5 Exceed Customer Expectations

Solution 2: Expert Services

⌫ Provide support and educational services to the engineering community

⌫ Offer design review services and provide input on sequences, points lists and specifications

⌫ Review Bid Documents and write good clear RFIs early in the process

Customer & Design Team

Controls HVAC Fire

Security

Lighting

Power Mgmt

Mechanical Contractor

Electrical Contractor

⌫ Windows⌫ Raised Floor⌫ etc

GeneralGeneral Behave more like consulting experts, less like the proverbial Crooks

Be professional and deliver on Performance Specifications

Submit proper checkout and commissioning documentation to Consultants

Make Buildings Work

Solution 3:

Deliver as Promised

Quality Assurance…

⌫ Apply ASHRAE Standards

⌫ Due diligence on installations and checkout practices

⌫ Tune loops and set up trends during checkout and commissioning

⌫ Work with Designers as fellow engineers, not combative contractors

⌫ Review Checkout Sheets

⌫ Verify that field devices match the specification

Working Together Working Together

we can deliver we can deliver

better design and better design and

construction construction

projects and the projects and the

High Performance High Performance

Buildings that Buildings that

Owners are Owners are

paying for.paying for.

Temperature Controls“Why Don’t They Work?

Q & A