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Overview of LBNL’s High-Tech Buildings
Project Activities
Bill Tschudi and Tim Xu
April 21, [email protected]@lbl.gov
Diverse Support
California Energy Commission Labs 21 New York State Energy Research and
Development Authority (NYSERDA) Northwest Energy Efficiency Alliance (NEEA) Public Utilities California Institute for Energy Efficiency (CIEE) Industrial Technology Research Institute (ITRI) Montana State University
Industry Collaborations
ASHRAE (lab, cleanroom, data center TC’s) IEST (minienvironment, fan-filter units) Air Movement and Control Association (AMCA) Silicon Valley Manufacturers Group 7X24 Exchange Organization Uptime Institute ITRI (Industrial Technology Research Institute,
Taiwan) Sematech
Research Collaborations
University of California UC Merced Campus
Cornell University Demand Controlled Filtration
Georgia Tech CEETHERM
State University of New York Data Center Air Management
Industrial Technology Research Institute Energy Benchmarking Fan-Filter Unit testing
Energy Intensive High-tech Buildings
Cleanrooms
Data CentersLaboratories
Energy Benchmarking
Enables comparison to other similar facilities
Establishes baseline to track performance over time
Prioritizes where to apply energy efficiency improvement resources
Identify better performing systems Identify maintenance and operational
problems Leads to operational cost savings
Some Results:
Energy End Use in Cleanrooms
Facility 1
Hot Water & Steam23%
Chilled Water19%
Cleanroom Fans16%
Other Misc.8%
Process13%
Cleanrooom Lights
1% Compressed Air & Process Vacuum
6%
Office (Lights, Plugs)
9%
Facility 2
Hot Water, Steam and Cafeteria
17%
Total Chilled Water20%
Cleanroom Fans27%
Other Misc.10%
Process9%
Cleanrooom Lights
1% Compressed Air
7%
Office (Lights, Plugs)
9%
Facility 3
Hot Water & Steam
7%
Office (Lights, Plugs)
9%
Process Utilities17%
Cleanrooom Lights
1%
Process35%
Other Misc.6%
Cleanroom Fans11%
Total Chilled Water18%
Air Recirculation Comparison
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
Fac. AClass 10
Press.Plen.
Fac. AClass100
Press.Plen.
Fac. B.1Class100
Ducted
Fac. B.1Class
100 FFU
Fac. B.2Class100
Ducted
Fac. B.2Class
100 FFU
Fac. CClass100
Press.Plen.
Fac. DClass 10Ducted
Fac. EClass
100 FFU
Fac. EClass100
Press.Plen.
Fac. FClass 10
Press.Plen.
Fac. FClass 10
Press.Plen.
Fac. FClass 10
Press.Plen.
Fac. FClass10k
CFM
/ kW
(hig
her i
s be
tter)
Averages (cfm / kW)FFU: 1664
Ducted: 1733Pressurized Plenum: 5152
Air-change Benchmarks
0
100
200
300
400
500
600
700
Fac. AClass 10
Press.Plen.
Fac. AClass100
Press.Plen.
Fac. B.1Class100
Ducted
Fac. B.1Class100 FFU
Fac. B.2Class100
Ducted
Fac. B.2Class100 FFU
Fac. CClass100
Press.Plen.
Fac. DClass 10Ducted
Fac. EClass
100 FFU
Fac. EClass100
Press.Plen.
Fac. FClass 10
Press.Plen.
Fac. FClass 10
Press.Plen.
Fac. FClass 10
Press.Plen.
Fac. FClass10k
Air
Cha
nges
per
Hou
r
Make-up Air System Comparison
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Facility AClass 10
Facility AClass100
FacilityB.1
Class100
FacilityB.2
Class 10
FacilityB.2
Class100
Facility CClass100
Facility DClass 10
Fac.E.1.1Class100
Fac.E.1.2Class100
Fac. F.2Class 10
*
Fac. F.3Class 10
Fac. F.1Class 10
CF
M /
kW
(h
igh
er
is b
ett
er)
Chilled Water Systems
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
WaterCooled
42F
Air Cooled42F
Air Cooled40F
Air Cooled48F
Air Cooled50F
WaterCooled
40F
WaterCooled
38F
WaterCooled
36F
WaterCooled
44F
WaterCooled
43F
Fac. A Fac. B.1 Fac. B.2 Fac. B.2 Fac. B.2 Fac. C Fac. D Fac. E.1 Fac. E.2 Fac. F
kW
/ to
n (
low
er
is b
ett
er)
Cooling Tower
CW Pumps
CHW Pumps
Chiller
UPS Efficiency
UPS Efficiency
0
20
40
60
80
100
0 20 40 60 80 100
Load Factor (% )
Eff
icie
nc
y (
%)
Benchmarking vision
On-line benchmark results that anyone can access for comparison.
We’d like to incorporate benchmark data that others have.
Primarily interested in building systems efficiency metrics – may include production metrics if there is interest.
Data reporting will be anonymous.
Tools and Publications
Cleanroom Programming Guide Laboratory Design Guide Design Intent Tool Labs 21 Benchmarking Tool Energy Research Roadmaps
Available now from LBNL website:
Case Studies/Charrettes/Project Review
Various Industries and Institutions Cleanroom Case Studies Laboratory Case Studies Data Center Case Studies Charrettes and project reviews:
IBM Genentech Sandia NEEA (fab of the future)
HP
LBNL Molecular Foundry
UC Merced Campus
Laboratories for the 21st Century
Annual Conference – October 5-7, St.Louis
Training Seminars – nationwide
Labs 21 Partners
Tool kit Lab Design Guide Design Intent Tool
Website: http://www.labs21century.gov/
Energy Benchmarking Tool
National database of lab energy use data
Web-based input and analysis
Currently approximately 40 facilities
Building level data (e.g. Site BTU/sf)
System level data (e.g. W/cfm)
Energy Benchmarking Tool
Data input requirements
Location Type Area Hours of operation Energy use Peak loads System characteristics Efficiency features
Benchmarking Tool – Analysis
Current Project Activities
CleanroomsLaboratories
Data Centers
Current Cleanroom Activities
Energy benchmarking and best practices identification
Demand controlled filtration Fan-filter test procedure Investigate efficiency opportunity in
minienvironments
Demand Controlled Filtration
Pilot study in LBNL cleanroom - completed
Workshop being planned to review the concept with industry
Alternate methods of recirculation setback investigated
Demonstration in an operating industry cleanroom (possibly Lam Research)
Fan-Filter Unit Test Procedure
Draft test procedure for energy performance issued for comments. Once in place, FFU’s performance can be measured by the standard test and will have a basis for “apples to apples” comparisons and owner specification.
IEST is developing a more comprehensive procedure
CA utility is interested in using the procedure to establish baselines for incentives
FFU manufacturers encouraged to volunteer their units for testing
Pressure vs. Airflow Velocity
Airflow Speed at FFU Exit (m/s)
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
FF
U P
ress
ure
Ris
e (
Pa
)
0
100
200
300
400
500
600
700
FFU001FFU002FFU003FFU007FFU009FFU010FFU011FFU013FFU018FFU027
Total “Pressure Efficiency”
Airflow Speed at FFU Exit (m/s)
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
To
tal P
ow
er
Eff
icie
ncy
(%
)
0
5
10
15
20
25
30
35
FFU001FFU002FFU003FFU007FFU009FFU010FFU011FFU013FFU018FFU027
FFU Energy Performance IndexW/cfm @ 0.5” Pressure
0
5
10
15
20
25
30
0% 20% 40% 60% 80% 100%
Percentile
EP
I (W
per
m3 /min
)
0.000.050.10
0.150.200.250.30
0.350.400.450.50
0.550.600.650.70
0.750.800.85
EP
I (W
/cfm
)
FFU Energy Performance IndexW/cfm @ 70 fpm Face
0
5
10
15
20
25
30
0% 20% 40% 60% 80% 100%
Percentile
EP
I (W
per
m3 /min
)
0.000.050.10
0.150.200.250.30
0.350.400.450.50
0.550.600.650.70
0.750.800.85
EP
I (W
/cfm
)
Minienvironment Investigation
Examine efficiency opportunity in selected minienvironment(s)
Partner with Asyst
Collaborate with Sematech
Develop strategies to improve efficiency
Minienvironment Investigation
Identify opportunities to improve overall facility energy efficiency
A field-study site is being sought
A demonstration in operating facility will be proposed to the CA Energy Commission
Current Laboratory Activities
Energy Benchmarking and Best Practices Identification
Low Flow Fume Hood Development Overcoming Barriers (CAL/OSHA) Side-by-Side Testing 3 Industrial Demonstrations
Better Fume Hood Containment at 40% Less Exhaust flow
And better worker safety
Current Data Center Activities
Energy Benchmarking and Best Practices Identification
Self Benchmarking Protocol Investigate Efficiency Opportunity in
UPS Systems Investigate Efficiency Opportunity in
Power Supplies
Additional Activities
Planning and Scoping Demonstration Projects Controlling air flow based upon particle counts
(Lam Research) Fan-filter testing Efficiency improvement in mini-environment
(Asyst, Jazzsemiconductor) Flow visualization using helium bubbles Others ?
Technology Transfer
Sematech input to LBNL project
Ram Mallela and Phil Naughton are on the project advisory committee for the CEC project
Others are welcome to participate The committee can recommend changes
in direction Next CA project advisory meeting – May
13 Participation in Labs 21 is welcome also
Questions?
Bill Tschudi Tim Xu
[email protected] [email protected]
510-495-2417 510-486-7810
Website: http://ateam.lbl.gov
