Chemistry Building RCx

Presenters:

Bob Kilgore

Matthew McReynolds

Brenna Goode

CHEMISTRY BUILDING RCX

Project History

The Challenge?

PH 1 Starts PH 2 Ends

FLOOD

Utility & Energy Use

5,827,190 kWh

7,945,346 kWh

26% Increase


36,467 MMbtu

40,956 MMbtu

11% Decrease

15,828 MMbtu

46,900 MMbtu

196% Increase


37,268 MMbtu

46,900 MMbtu

26% Difference Due to Excess Flow


How Did Chemistry Compare?

PH 1 Starts PH 2 Ends

FLOODLabs21 Benchmark Data


Fume Hood Testing

Processes

Over 250 Hoods Currently Operational

• Verify sash velocities at multiple positions• Compared to most recent EHS testing reports• Verify current hood use

AHU Testing

It’s All about building trust• Verify actuator extents and mid-point stroke positions

• 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

Processes

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

Single point of control for heat recovery creates one satisfied AHU and three unsatisfied AHUs

AHU Heat Recovery Control

Findings

Chilled Water System Investigation

Findings

• AHU Control Sequences• AHU Coil Capacities

• Pumping Capacity

• Historical Weather Data

Chilled Water System

Findings

• AHU Control Sequences

Reduce Discharge Air Temperature Based on Return/Exhaust Humidity Level.

+3°F55°F52°F 50°F47°F

Chilled Water System

Findings

• AHU Coil CapacitiesModeling 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

Chilled Water System• Pumping Capacity

Building Chilled Water Users

AHU Tag QuantityDesign Flow

gpmControl

Valve SizeModel Number

Max GPM 5-70 psig

Actuator With a 150 PSI Close Off

Weight (lbs)

Control Signal

Fail Safe Action

SAHU-1 1 785 8 8"-IDP-415-05-L 900 NEPTRONIC UB9040 575 0-10V NC NCSAHU-2 1 530 6 6"-EDP-340-05-L 590 NEPTRONIC UB8040 240 0-10V NC NCSAHU-3 1 785 8 8"-IDP-415-05-L 900 NEPTRONIC UB9040 575 0-10V NC NCSAHU-4 1 395 6 6"-EDP-280-05-L 420 NEPTRONIC UB8040 240 0-10V NC NCSAHU-5 1 535 6 6"-EDP-340-05-L 590 NEPTRONIC UB8040 240 0-10V NO NO

EXISTING AHU (NW) 1 2050 10 10"-JDP 2200 NEPTRONIC UB9040 1200 0-10V NC NCPROCESS HEAT EXCHANGER 1 341 6 6-EDP-280-05-L 420 NEPTRONIC UB8040 240 0-10V NC NC

AHU-1 (Auditorium) 1 25 ?? ?? ?? ?? ?? ?? ?? ??FC-1 2 1.5 1/2 1/2"-FDP-4-05-H 2 BELIMO LF24-SR 5 0-10V NC NCFC-2 5 3 1/2 1/2"-FDP-4-05-H 3 BELIMO LF24-SR 5 0-10V NC NCFC-4 1 4 1/2 1/2"-FDP-4-05-H 4 BELIMO LF24-SR 5 0-10V NC NCFC-5 1 4.5 3/4 3/4"-HDP-6-05-H 6 BELIMO LF24-SR 10 0-10V NC NC

TOTAL FLOW = 5459 GPMPUMP CAPACITY = 3600 GPM

CAPACITY SHORTFALL= 1859 GPM

Findings

Chilled Water System• Historical Weather data

Airflow Target Coil Target CoilCFM GPM Gallons DB WB EWT LWT Delta T LAT LAT Tons Tons57,067 745 44,700 90.4 73.2 44.9 56.3 11.4 46.5 48.1 400.51 353.13 5.256,907 745 558,750 87.4 74.1 45.1 56.9 11.8 46.5 48.5 416.87 365.09 65.256,906 745 2,592,600 84.3 73.2 45.2 56.5 11.3 46.5 48.5 400.47 351.44 302.756,874 745 6,302,700 78.1 70.4 45.0 55.1 10.1 46.5 47.8 345.74 314.75 735.956,814 745 12,583,050 79.9 69.2 45.0 54.5 9.5 46.5 47.6 322.61 295.68 1,469.256,714 745 16,024,950 76.1 67.0 45.0 53.5 8.5 46.5 47.3 284.43 264.26 1,871.156,598 745 20,360,850 72.0 64.9 44.9 52.5 7.6 46.5 46.9 248.71 234.59 2,377.356,547 745 20,562,000 67.0 61.2 44.9 50.9 6.0 46.5 46.5 190.73 185.71 2,400.856,530 530 14,946,000 62.0 56.9 44.8 50.5 5.7 46.5 46.5 129.07 125.40 1,745.1

Coil Model InputsFlow EAT CoilAirflow Target Coil Target Coil Calc

CFM GPM Gallons DB WB EWT LWT Delta T LAT LAT Tons Tons Mmbtu57,067 425 25,500 90.4 73.2 44.9 62.7 17.8 51.5 51.4 341.79 314.78 3.056,907 470 352,500 87.4 74.1 45.1 62.2 17.1 51.5 51.4 358.29 334.12 41.256,906 460 1,600,800 84.3 73.2 45.2 61.8 16.6 51.5 51.4 341.89 318.58 186.956,874 405 3,426,300 78.1 70.4 45.0 61.1 16.1 51.5 51.5 287.19 272.36 400.156,814 375 6,333,750 79.9 69.2 45.0 61.0 16.0 51.5 51.5 264.11 250.39 739.556,714 335 7,205,850 76.1 67.0 45.0 60.4 15.4 51.5 51.5 226.02 215.14 841.456,598 295 8,062,350 72.0 64.9 44.9 59.7 14.8 51.5 51.5 190.41 181.39 941.456,547 227 6,265,200 67.0 61.2 44.9 58.5 13.6 51.5 51.5 132.47 128.47 731.556,530 127 3,581,400 62.0 56.9 44.8 57.8 13.0 51.5 51.5 70.83 68.68 418.2

SAHU-1 Coil Model Inputs (ECM-10)Flow EAT Coil

Data From University of Iowa Chilled water Plant PI System

Findings

Findings• Historical Weather data

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% full design capacity.

Findings

Unit is running at approximately 60% full design capacity.

ECM-11Fix AHU-NW Discharge Air Temperature

Sensor

• Recalibrate DAT sensor to read true value of conditioned air.

• This measure was implemented during study.

Recommendations

Results

ECM-11

ECM-11Results

1 Advanced AHU Heat Recovery Control $164,000 - 720 402 $21,500 7.6 22 Singe Loop AHU Discharge Air Temperature Control $11,000 - 834 601 $28,300 0.4 23 Dynamic Duct Static Pressure Reset $57,000 101,535 776 1,115 $48,800 1.2 24 Discharge Air Temperature Set Point Reset $42,000 (68,205) 4,169 3,821 $156,100 0.3 25 Dynamic Pump Differential Pressure Reset $13,000 13,784 - - $1,200 10.8 26 Teaching Lab Occupancy Air Flow Reset $96,000 33,257 487 13 $10,900 8.8 27 Reduce Minimum Laboratory Ventilation Rate During Occupied Hours $108,000 83,226 1,880 1,414 $72,300 1.5 28 Decommission Unused Fume Hoods $18,000 18,876 609 216 $16,700 1.1 2,39 Re-Balance Over-Exhausted Fume Hoods $24,000 45,783 1,381 2,508 $88,600 0.3 210 Decommission Existing AHU Dehumidification Sequences $5,000 41,647 2,326 3,346 $124,100 0.011 Fix AHU-NW Discharge Air Temp Sensors $1,000 - 3,711 1,069 $85,800 0.0 412 Reduce Classroom Lab Fume Exhaust Levels During Unoccupied Hours $131,000 30,465 435 7 $9,700 13.5 213 Reduce Minimum Humidification Setpoint $7,000 - 853 - $13,600 0.5 2

$677,000 $677,600 1.0

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 0.084$ 3. This measure is intended to identify approximate itemized savings of removing one (1) hood from operation. 15.91$ 4. This measure was implemented during the summer of 2012. 24.98$

TOTAL

Estimated Blended Marginal Rates (Fiscal Year 2013)

/kWh Elec/MMBtu Steam/MMBtu Chilled Water

Simple Payback

YearsNotes Electric

(kWh) Steam

(MMBtu) Chilled Water

ECM Number

Energy Conservation Measure (ECM)

Estimated Implementation

Cost1

Estimated Annual Utility Savings Estimated Annual Cost Avoidance

Recommendations

• Uncertainty of purpose

• Unrealistic solutions

• Overly burdensome implementation

• Impact on research and instrumentation

• Impact on the instructional mission

User Concerns

7 of 13 ECMs required coordination with building users and lab equipment:

4 Discharge Air Temperature Set Point Reset $42,000 (68,205) 4,169 3,821 $156,100 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 Decommission Unused Fume Hoods $24,000 18,876 609 216 $16,700 1.4 2,3

10 Decommission Existing AHU Dehumidification Sequences $5,000 41,647 2,326 3,346 $124,100 0.0

12 Reduce Classroom Lab Fume Exhaust Levels During Unoccupied Hours $131,000 30,465 435 7 $9,700 13.5 2

13 Reduce Minimum Humidification Setpoint $7,000 - 853 - $13,600 0.5 2,4$413,000 $403,400 1.0

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 0.084$ 3. Costs associated with this measure include both the decommissioning and recommissioning effort of hood identified. 15.91$ 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. 24.98$

Electric (kWh)

Steam (MMBtu)

Chilled Water

(MMBtu)

TOTAL

ECM Number

Energy Conservation Measure (ECM)

Estimated Implementation

Cost1

Estimated Annual Utility Savings

Notes

Estimated Blended Marginal Rates (Fiscal Year 2013)

/kWh Elec/MMBtu Steam/MMBtu Chilled Water

Estimated Annual Cost Avoidance

Simple Payback

Years

Recommendations

• reduce the reheat load: reset the AHU Discharge air set points upward when dehumidification is not necessary

ECM-4Discharge Air Temperature set Point Reset

Room Number Space Use Description

Teaching LaboratoryW254 Lab Equipment RoomW76 Lab Analytical RoomW182 Research LabW174 Research LabE127A-1 Core Collegiate LabW290A Classroom Projection RoomE236 Electrical ClosetW338 Lab Computer Server Room

W344Class Lab Preparation RoomW428

W444 Classroom LaboratoryE303 Research Lab (Dry)E309 Research Lab (Dry)W436 Collegiate - Special Procedures

• Individual spaces identified

• Majority of concerned spaces currently have supplemental cooling systems

ECM-6/ECM-12Teaching Lab Occupancy Air Flow Reset

User Discussion

• 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

ECM-6/ECM-12Teaching Lab Occupancy Air Flow Reset

• Minimum Turndown Capabilities of VAV’s

• Temperature Control Infrastructure

• Reviewed Viable Timeframes

Confirmed through sample of Shop Drawings

• Add Controllers (Nae)

• Each Room Program Individually Modified Winter And Spring Break

User Discussion

ECM-7Reduce 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-7Reduce Minimum Laboratory Ventilation Rate

During Occupied Hours

• Minimum Turndown Capabilities of VAV’s

• Temperature Control Infrastructure

User Discussion

ECM-8Decommission Unused Fume Hoods

• This measure identifies the savings potential of decommissioning Individual Fume Hoods

Scope Would Include-

1. 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-8Decommission Unused Fume Hoods

Five Rooms Identified

E124

W100

W105

W109

W147

User Discussion

ECM-10Decommission 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

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.

Decommission Existing AHU Dehumidification Sequence

User Discussion

User Discussion

• Lower humidification set point from 30% to 20% RH

• Based on equipment environmental tolerances, this measure was not implemented.

ECM-13Reduce Humidification Set Point

User Discussion

• Engaged building participants; early and often

• Free-flow of information

• Responded quickly to concerns

• Took time to learn

Actual Implementation

Questions?

Thank You

Documents

Chemistry Building RCx