Continuous Commissioning SM Report. For. Wing 86, Chemistry Complex (Building # 376) Hui Chen Song Deng Homer L. Bruner, Jr., CEM.

Transcription

1 Continuous Commissioning SM Report For Wing 86, Chemistry Complex (Building # 376) By Hui Chen Song Deng Homer L. Bruner, Jr., CEM Contact: Song Deng ( ) Homer L. Bruner, Jr. ( ) July 2000

2 Table of Contents I. INTRODUCTION... 1 II. AIR HANDLING UNITS... 1 A. GENERAL AHUS Observed (Identified) Operation Problems and Commissioning Activities CC SM Measures for AHUs Recommendations... 2 B. SPECIAL AHUS ISSUES The heating and cooling problems of 9 outside air handling units The Coupled Control Problems of OAHUB-1 and OAHUB OAHUB-4 and VFD... 6 III. LABORATORIES... 7 A. GENERAL LABORATORIES Introduction Problems Identified and CC SM Measures Recommendations... 8 B. SPECIAL LABORATORIES ISSUES Labs 2210 and Troubleshooting for different labs Glass Workshop Thermostats IV. WHOLE BUILDING PRESSURE DISTRIBUTIONS Introduction Measured pressure distributions of labs, chases and hallways Verification of DP transmitter for different exhaust fans Calibrated DP Transmitters for the central heater exhaust systems and the general exhaust systems Reset set points of static pressure for the central heater exhaust systems and the general exhaust systems Problems Recommendations V. CHILLED WATER & HOT WATER SYSTEMS The sequence of operations Problems Identified Recommendations VI. COMPARISON OF PRE-CC SM AND POST-CC SM HOT WATER, CHILLED WATER AND ELECTRICITY CONSUMPTION Continuous Commissioning SM activity periods are as follows: Measured data graphs (hot water, chilled water and whole building electricity for Pre- CC SM and Post-CC SM periods Comparison of Pre-CC SM and Post-CC SM periods Recommendations APPENDICES APPENDIX A. A COMPLETE LIST OF AIR HANDLERS AND THEIR SERVICES APPENDIX B. HOT WATER PUMP INFORMATION APPENDIX C. 86 WING FH SUPPLY MOTOR REPLACEMENT SCHEDULE APPENDIX D. DESIGN LAB AIR BALANCE INFORMATION APPENDIX E. TROUBLESHOOTING REPORTS FOR DIFFERENT LABS ON DIFFERENT DATA Troubleshooting for Lab 2206 (February 21, 2000) Troubleshooting for Lab 2213 (February 21, 2000) Troubleshooting 2504 (March 3, 2000) Troubleshooting for lab 2520, 2519 and 2119 (March 24, 2000)

3 5. Troubleshooting for Room 2103 (March 31, 2000) Zone 5 of AHU-G2 (March 31, 2000) Troubleshooting for lab 2119 (March 31, 2000) Troubleshooting Noise in Labs 2310 and 2312 (June 2, 2000) Troubleshooting for lab 2206 (June 9, 2000) APPENDIX F. AIRSIDE MEASUREMENT OF AHUS APPENDIX G. ELECTRICITY, CHILLED WATER AND HOT WATER CONSUMPTION VS. TEMPERATURE GROUP BY PRE-CC SM /POST-CC SM Electricity Consumption Chilled Water Consumption Hot Water Consumption... 60

4 I. INTRODUCTION The Chemistry Complex, Wing 86, is a chemistry laboratory and classroom building with a total floor area of 115,797 square feet. It has six levels, (B, G, 2, 3, 4 and 5,) as well as two penthouses. The basement consists mainly of two mechanical rooms, a workshop, glass shop and three chemistry labs. The ground floor is made up of classrooms, offices, and a study/library area, but no labs. Floors, 2 through 5, are composed primarily of chemistry labs. There are 42 variable airflow fume hoods and 85 constant airflow fume hoods. There are 105 fume hoods with makeup air (as supply air) to each hood among a total of 127 fume hoods in the building. There are 49 air handling units (AHUs) in the building, including 16 outside air handling units (OAHUs). Fifteen of the OAHUs are equipped with variable frequency drives (VFDs). The rest of the AHUs in the building are constant air volume. Most of these air handlers are small, and dedicated to specific areas, such as a room, hallway or for hood make-up air. There are some larger ones, which serve half floors. See Appendix A for a complete list of air handlers and their service. Major AHU s and pumping systems are controlled by energy monitoring control system (EMCS) with Siemens interface. There is a large mechanical room (2010) in the basement, which contains nine AHUs, as well as hot and chilled water pumps and other equipment. There is also a smaller mechanical room in the basement that contains three AHUs. The other mechanical rooms are on the ground floor (2105 And 2115), on the fourth floor (2406 and 2415), and the two penthouses on the roof. Two constant speed hot water pumps (MAHWP-1, 3.0 hp; HSHWP-1, 7.5 hp) separately supply hot water to the makeup air handling systems and all the makeup air heating coils for the fume hoods. Two other constant speed hot water pumps (VAVHWP-1, 3 hp, MZHWP-1, 7.5 hp) separately provide hot water to all the terminal VAV boxes and AHUs. Two variable speeds chilled water pumps (each 60 hp) supply the chilled water from the main campus loops to all of the AHUs. II. AIR HANDLING UNITS A. General AHUs 22 of the 49 AHUs are large ones that provide most of supply airflow for this building. There are 15 AHUs with VFD control and 19 of the AHUs are controlled by EMCS with Siemens interface. 1

5 1. Observed (Identified) Operation Problems and Commissioning Activities This section presents the operation control problems that were discovered during the commissioning activities. Based on detailed surveys and investigation, we found the following AHUs have these problems in common. In the existing control program, we found a combination of new and old program lines. Some of the points that were removed were still in the program and some duplicate lines are in each program; Failed static pressure sensors resulted in VFDs at constant speed (such as OAHUB-6) and failed or incorrect temperature sensors left control valves in unchanging positions; Incorrect set points in program (VFD speed, discharge temperature, control valve, damper, etc.); Damper positions often did not match the signal from controllers; Sticking chilled water or hot water valves; Electronic signal ranges (4 ~ 20 ma) do not match VFD s ranges (An example would be OB-1 and OB-2. We have checked and found that their ranges need to be calibrated). There is a total of 19 duct transfers or boots that need to be replaced (from air handler fan to discharge duct). Dirty filters, loose belts, extremely clogged hardware cloth for outside air intake; Dirty pre-heat coils and cooling coils which restrict air flow; 2. CC SM Measures for AHUs We verified temperature sensors and static pressure sensors for each AHU; Took airside measurements for each AHU (see Appendix F); Cleared some duplicate lines from a combination of new and old program lines in the existing control programs; Deleted some of the dead points that were still in the program; Corrected some loop and table statements; Changed some set points, damper and control valve ranges (cold deck, reheat, static pressure set points; supply damper and return water control valve range). Changed filters; Washed hardware clothes; Cleaned pre-heat coils and cooling coils; 3. Recommendations A total of 19 duct transfers or boots (airhandler fan to discharge duct) need to be replaced. This has been reported to area maintenance 2, but has not been acted upon. Check and adjust each electronic signal range that controls an AHU's VFD. There are approximately 30 small-coupled control AHUs in the ceiling. We need to adjust spring ranges and calibrate the thermostats to the dead band between cooling and heating. Some AHUs are cooling only, these thermostats also need to be calibrated. 2

6 B. SPECIAL AHUs ISSUES The above listed problems are in common for all of the AHUs, the following problems are special to some of the AHUs. 1. The heating and cooling problems of 9 outside air handling units Nine AHUs are 100% outside air handling units (OB-4, OB-5, OB-6, O4-2, O4-3, O4-4, OPH-1, OPH-2 AND OPH-3). They have the same control drawings and sequence of operation from the design control drawings, field survey and existing control programs. Design Information The design control drawings show that each of the 9 OAHUs has two modes, preheating (NO; 3-8 psi) and cooling (NC; 9-13 psi). By sequencing these modes, the system can be placed into a pre-heating only or cooling only mode as needed. Note that the pre-heating valve is fully shut before the cooling valve starts to open. Temperature sensor through the SCU will modulate the pre-heat and chilled water valves in sequence to maintain the discharge temperature at a setpoint of 55ºF. The problems and the reason for the heating and cooling fighting problems Table 1 shows 9 outside air handling units have heating and cooling fighting problems. One LOOP statement controls two output devices (different spring ranges for pre-heating and chilled water valves). The reasons for the heating and cooling fighting are as follows: MCC positioners and PMV valve positioners need to be calibrated or adjusted; Pneumatic control lines are routed to a wrong designation; Some pneumatic elements were disconnected and not removed. 3

7 Table 1 Investigation Table for 9 OAHUs for Wing 86, Chemistry Complex OAHU NAME Valve Range (Psi) B-4 CW: 2 14 PHW: 5 7 B-5 CW: 6 16 PHW: 5 14 B-6 CW: > 12 PHW: CW: 4 13 PHW: CW: 8 15 PHW: >3 4-4 CW: 4 16 PHW: 6 14 PH-1 CW: 6 17 PHW: 3 15 PH-2 CW: 6 16 PHW: 3 15 PH-3 CW: PHW: 3 12 Measured Value (Psi) Afternoon of 3/23/00 Valve Pressure (Apogee) (Psi) Early Morning of 3/23/ Discharge Temp. (Apogee) (F) Early Morning of 3/23/00 Note Two new valves PMV Valve Positioner is bleeding air from controller PMV Valve Positioner is bleeding air from controller PMV valve Positioner is not used Switching Relays were disconnected No signal air line (from controller) is connected to the PH Valve; Switching Relays were disconnected PMV Valve Positioner is bleeding air from controller CC SM Measures We verified temperature sensors and static pressure sensors for each AHU and modified the existing control programs. Disconnected some existing pneumatic air lines and elements such as EP relay ( ), Positive relay MP and Gage; Installed new pneumatic air lines from DPV to chilled water valve and pre-heat valve; Adjusted PMV valve positioner to set chilled water valve range at 9 psi 13 psi and pre-heat valve range at 3 psi 7.5 psi. The results after CC SM measures Table 2 shows the results after Continuous Commissioning SM. The CC SM measures listed above solved the heating and cooling fighting problems of 9 of the outside air handling units. Recommendations Some PMV valve positioners need to be repaired or replaced as soon as possible. 4

8 Table 2 Valve Range Adjustments for 9 OAHUs for Wing 86, Chemistry Complex OAHU NAME Adjusted Valve Ranges (Psi) B-4 CW: PHW: B-5 CW: PHW: 4 8 B-6 CW: 9 15 PHW: CW: PHW: CW: 8 15 PHW: CW: PHW: 4 12 PH-1 CW: 9 13 PHW: 4 8 PH-2 CW: PHW: 4 8 PH-3 CW: PHW: 3 8 Valve Ranges Before Adjustment (Psi) CW: 2 14 PHW: 5 7 CW: 6 16 PHW: 5 14 CW: > 12 PHW: CW: 4 13 PHW: 5 10 CW: 8 15 PHW: >3 CW: 4 16 PHW: 6 14 CW: 6 17 PHW: 3 15 CW: 6 16 PHW: 3 15 CW: PHW: 3 12 Problems PMV Valve Positioner is Needed to Replace PMV Valve Positioner for Chilled Water Valve is Needed to Fix PMV Valve Positioner for Hot Water Valve is Needed to Replace PMV Valve Positioner for Hot Water Valve is Needed to Replace; New PMV Valve Positioner for Chilled Water Valve is Needed to Install; 2. The Coupled Control Problems of OAHUB-1 and OAHUB-2 As a result of renovation in 1995, the existing system was modified. The makeup air systems which were directly connected to the fume hoods were removed and OAHUB-1 and OAHUB-2 were combined to supply makeup air to labs 2210 and 2212 only. Currently OAHUB-1 and OAHUB-2 join together in a plenum on the supply side of the duct. Problems: OAHUB-1 was turned off because the supply air duct made a loud noise in room 2109; Airflow from OAHUB-2 back flows towards OAHUB-1; The control program for OAHUB-1 and OAHUB-2 was hunting (one cycle in one minute) and made a loud noise; The static pressure setpoint was 4 WG; Make up air dampers were hunting; Airflow stations for OAHUB-1 and OAHUB-2 deviate from the reasonable ranges; 5

9 CC SM Measures After verifying the 6 temperature sensors and 2 static pressure sensors for OAHUB-1 and OAHUB-2, it was found that a static pressure sensor for OAHUB- 1 was in a faulty position. Also it was found that the static pressure sensor for OAHUB-2 needed calibration; The makeup air damper ranges were reset in the PPCL program and the makeup air dampers were adjusted according to the actual damper s ranges; Turned on OAHUB-1, which was off early due to loop tuning (one cycle in one minute) and too much noise in office The PPCL modification and loop tuning (also corrected static pressure setpoint) three weeks ago prevented hunting and the office wall from shaking with the noise. Tuned VFD control loops for AHUs (OAHUB-1 and OAHUB-2) and make up air damper control loops for the labs (2210 and 2212); Deleted some of the points that were removed, but were still in the program; Cleared some duplicate lines from a combination of new and old program lines in the existing control programs; Changed static pressure setpoint from 4.0 WG to 3.0 WG; Set the two fan motor speeds at 100% to prevent backflow into OAHUB-1 (the horsepower and supply airflow of OAHUB-1 are less than OAHUB-2) and increased makeup airflow for labs 2210 and 2212 because they are too negative DP. Separated the contact of a metal stud (cut the extra part) on the top of an inner wall of room 2109 from two supply air ducts to prevent wall shaking or vibration. Recommendations Airflow stations for OAHUB-1 and OAHUB-2 need to be calibrated; Whenever labs 2210 and 2212 are fully used (each fume hood is being used), the total makeup air flow from OAHUB-1 and OAHUB-2 (each one running at 100% speed) is not large enough to maintain the lab air balance. In order to solve the negative pressure problem for these two labs, a renovation such as increasing the makeup airflow capacity of the AHUs is recommended. 3. OAHUB-4 and VFD Problems We found that the VFD equipment of OAHUB-4 was installed many years ago, unfortunately EMCS did not use the existing VFD to control the fan speed of OAHUB-4. Furthermore, we found no control program in the field panel and no static pressure sensor on the supply air duct. CC SM Measures Wrote a loop and a table statement; Installed a static pressure sensor for VFD control; Inserted several point names and set point in PPCL program; 6

10 III. LABORATORIES A. General Laboratories 1. Introduction There are 125 fume hoods in the 63 labs and workshops in this building. The 34 fume hoods in the 11 labs on the second floor and 6 fume hoods in labs 2310 and 2312 on the third floor are variable air volume (VAV) hoods. All other fume hoods are constant air volume (CAV) fume hoods. Some labs have three sources of supply/makeup air to the labs. One from the VAV boxes, one directly from the hood makeup fans, and from the OA AHUs with around 60F air. The exhaust from the hoods is also VAV. Most of the labs in the basement, the third floor, the fourth floor and the fifth floor have general exhaust grills which exhaust lab air to the south chase or north chase. The four existing vane-axial exterior chase exhaust fans on the roof are controlled through differential pressure transmitters, an averaging relay, and receiver controller. This equipment modulates the pitch of the fans in parallel operation to maintain a static pressure setpoint of 0.2 in WG with respect to outside. 2. Problems Identified and CC SM Measures 31 of the total 105 makeup air fan motors were bad (see Appendix C). This is one of the main reasons for negative lab pressures. We gave Homer and AM2 a list of the bad makeup air motors. We also measured the exhaust airflow, makeup airflow and conditioned airflow for the labs in the basement, on the second floor, third floor, fourth floor and fifth floor. We observed that makeup air was frequently restricted due to dirty filters and dirty pre-heat coils while exhaust air was still near design (there are no filters and no manual dampers in exhaust). This also contributed to the negative lab pressures. We already changed each makeup air filter. We gave Homer a list of dirty preheat coils. We have checked the exhaust damper position and the face velocities of the fume hoods. Of all the fume hoods (34 VAV fume hoods) checked on the second floor, almost 60% of all the fume hood s flow coefficients needed to be adjusted and 40% of all the fume hoods dampers needed to be adjusted and calibrated. We adjusted 20 fume hood s flow coefficients or calibrated 14 dampers for the VAV fume hoods. Most of the face velocities of the constant air volume fume hoods on the third, the fourth floor, the fifth floor and basement deviated from 100 FPM face velocity due to loose exhaust fan belts, low motor RPM, etc. For the basement and first floor we balanced air flows from the multizone units so that supply air temperature was 5 to 7ºF higher than cold deck temperature. This provides excess capacity when the zone loads increase. 7

11 We checked VAV boxes and found about 30 actuators were broken. The broken actuators cannot help these VAV boxes maintain lab conditions. We gave Area Maintenance II a list of these broken actuators. We calibrated static pressure sensors and replaced a failed sensor. Several set points were reset. The reset criterion is based on the measured static pressure distribution and actual requirements for all the labs and the whole building. 3. Recommendations The final air balance needs to be done after each pre-heat coil is cleaned and bad makeup air fan motors are replaced. Bad actuators need to be replaced for VAV boxes and the damper range needs to be adjusted according to signal pressure from the controller. In addition, the conditioned airflow from VAV boxes needs to be reverified. B. Special Laboratories Issues Above problems and CC SM measures are in common with almost each lab. The following labs have their own special problems and CC SM measures. 1. Labs 2210 and 2212 During our investigation and commissioning of the Chemistry 86 Wing we found several problems with the AHU controls and individual lab air balance controls. This illustrates typical problems with the AHU control, lab air balance control and the fume hood exhaust flow readings for labs 2210 and 2212, which are the larger labs upgraded to Landis & Staefa DDC controls in Original HVAC Setup According to the original HVAC setup on the second floor, each fume hood in labs 2210 and 2212 had its own makeup air and exhaust air fans. In addition, cold air through the VAV terminal reheat boxes and makeup air through the linear slot diffusers supplied make up air to the labs. At the AHUs level, OB1 served labs 2210 and 2212, OB2 served labs 2204 and 2206, and OB6 supplied makeup air and cold air to all four labs. New HVAC Setup During the renovation in 1995, the makeup air ducts directly to the fume hoods were removed and OB1 and OB2 were combined to supply makeup air to labs 2210 and 2212 only. The OAHU G1, which previously supplied makeup air to the glass shops in the basement, was re-ducted to supply makeup air to labs 2204 and OB6 was still left to supply cold air to the VAV boxes for labs 2204, 2206, 2210, and The individual hoods exhaust fans were also removed and their ducts tied into a common header on the roof through modulating dampers. Control Program Scheme Exhaust airflow from each fume hood is totaled. This total exhaust air from the hoods then determines the makeup air requirement. The total makeup air is set 200 cfm 8

12 less than the total exhaust air. This 200 cfm difference maintains a slight negative pressure in the lab. The makeup air to the labs through the slot diffusers and cold air from the VAV boxes through the round diffusers are controlled by PXPs (PXP is a controller that transforms a DDC signal from the computer to a pneumatic signal to the damper actuator). The VAV boxes up to a maximum of 3200 cfm first supply the make up air to the labs. Any higher air flow requirement is then met by the slot diffusers. The VAV boxes also control room temperature, but temperature control is secondary to the air balance control. As demand for make up air increases, more air is supplied to the labs. If this results in a lab temperature drop, a terminal electronic controller (TEC) will give a signal to the reheat control valve to increase the supply air temperature to satisfy the lab temperature requirement. Problems Identified In the original control program, we found several problems: In the existing control program, we found a combination of new and old program lines. Some of the points that were removed were still in the program and controlling the AHUs. The cold supply airflow through the VAV boxes was zero to both the labs 2210 and This was partly due to wrong pressure range setpoints in the control program. The activation range of control dampers on the VAV boxes is NC 8 to 13 psi. However, the control program pressure range was only 3 to 8 psi and even in full open command did not provide enough pressure to the dampers to open. This was the case with both labs 2210 and When we started the investigation, lab 2210 was not in use and all the fume hoods were almost closed. However, lab 2212 was in full use and all the fume hoods were in use, resulting in excessive exhaust air. Because lab 2210 was not in use it only required a small amount of make up air, while lab 2212 required a lot of make up air to maintain 200 cfm lab difference. It was found that the PXP that controls the labs makeup airflow was bad for both the labs. The PXP for lab 2210 commanded the dampers full open resulting in positive pressure in that lab. The PXP for lab 2212 could not command the damper full open resulting excessive negative lab pressures. At the start of our investigation, lab 2212 was running in excess of 9000 cfm negative, while lab 2210 was positive. We also verified the makeup and cold airflow from the AHUs (OAHUB-1, OAHUB-2 and OAHUB-6). Airflow measurements from the OAHUB-1 and OAHUB-2 show that OAHUB-1 and OAHUB-2 do not have the potential to provide enough makeup airflow to maintain lab air balance. The two AHU measurements at 100% speed show that both labs still have large negative pressure problems after the above PXP problems were fixed. We found several operator display panels (ODPs) for the variable air volume (VAV) fume hoods were missing. For example, 6 of the 11 ODPs in lab 2212 are missing. According to the technicians in the lab, the reason is that these ODPs made noise, so they took them out. 9

13 CC SM Measures The control program was modified and old points and lines were removed. The fan speed was based on static pressure setpoints rather than airflows. This problem was fixed. The PXP damper command ranges were changed so that the dampers can modulate from fully open to fully closed. However, the minimum air flow setpoint will keep the dampers slightly open at all times. Bad PXPs were replaced. The negative airflow for Lab 2212 reduced from 9000 to 4000 cfm. Lab 2210 modulates the damper properly to maintain negative pressure. The actual lab exhaust from lab 2212 was very high because all the hoods were being used. The makeup airflow has a high limit setpoint and if actual exhaust airflow is higher than can be made up by makeup air, the lab will remain at higher negative pressure. Since we were not getting the required maximum airflows from the AHUs, we checked the belts, filters and coil conditions. We tightened the belts, replaced filters and cleaned preheat coils and cooling coils. This further improved the air balance. We reinstalled the missing eight ODPs for the variable air volume (VAV) fume hoods. 2. Troubleshooting for different labs We did troubleshooting for different labs during the period of Continuous Commissioning SM. Appendix E summarizes the different troubleshooting reports for different labs. 3. Glass Workshop Introduction The glass shop (Room 002) is approximately 2,400 ft 2. Currently AHUGS-1 supplies cooling air and OGS-2 supplies makeup air to the shop. Before the 1995 renovation, OGS-1 (9600 cfm) supplied makeup air to the glass shop and so did OGS-2 (3,200 cfm). During the renovation, OGS-1 was re-routed to supply makeup air to labs 2204 and There is a fume hood, a silvering sink exhaust hood, and ten canopy fume hoods, which relate to five exhaust fans in the glass shop. Table 3 shows the original design information and actual measured data. Problems before commissioning No exhaust airflow in three canopy hoods (exhaust fan PP17559 did not run) and face velocities of most of canopy hoods were low 20 ~ 40 FPM; OGS-2 did not run; DP in the glass shop was 0.28 WG; Mechanical room (2003) is too negative (DP) because OGS-2 directly sucks lots of air volume which is included in the little return airflow from the glass shop; 10

14 CC SM measures Adjusted each supply air damper in round diffuse (total 15); Adjusted each canopy hood damper in exhaust air ducts (total 8); Did exhaust airflow measurement for two supply AHUs, one fume hood (FHE ), and three exhaust fans (CHE-004-1, CHE-004-2, and CHE-004A-1). Table 3 shows the measured data. Turned an exhaust fan on (CHE-004A-1); Turned OGS-2 on after JP, Area Maintenance fixed VFD for OGS-2; Recommendations The following shows the different fume hood safety requirements for face velocity: Canopy fume hood face velocity: 50 ~ 70 FPM (G. Thomas Saunders: A User s Manual, Laboratory Fume Hoods); Silvering sink fume hood face velocity (capturing hood): 100 ~ 200 FPM (ASHRAE: 1995 Application Handbook); General fume hood face velocity: 100 FPM (Fume Hood Program, Environmental Health and Safety Department, Texas A&M University); Based on total exhaust airflow calculation for all fume hoods, current total exhaust airflow is not high enough. The exhaust airflow is expected to increase by changing fan belts, checking RPM and fully opening manual dampers; Compared design and actual makeup airflow requirements with current existing measured airflow. Makeup airflow to the shop from OGS-2 is too low to maintain shop air balance. The existing two air handling units (OGS-1 and OGS-2) do not have the potential to increase airflow to require or maintain satisfied shop conditions. Another renovation concerning increasing makeup airflow is recommended. The makeup air requirements for the lab cannot be met in a practical manner under the current duct system. The makeup air supply is currently dumped at the front door. This causes a breeze that circulates into the work area and causes the glass to break due to so much makeup air cooling the air where the glass is being heated up and shaped. It is the recommendation of ESL that this makeup air system be reconstructed to distribute the makeup air more evenly throughout this controlled environment. The silvering sink exhaust duct in the glass shop has a control damper installed. The glass shop uses the silvering sink infrequently and turns off the silvering sink exhaust when not in use. However, they report that when they turn off the silvering sink exhaust, fumes from the roof find their way into the room. We recommend the installation of a damper to protect the glass shop from dangerous fumes when or if the silvering sink is not in use. We also recommend the installation of the damper to limit the loss of conditioned air from the glass shop to the roof. This would also decrease the usage of the silvering sink exhaust fan and in turn, decrease the work and energy used by the makeup AHU. 11

15 AHU Name AHUG S-1 Table 3 Air Balance for Glass Shop, Chemistry Complex, 86 Wing (5/1/00) Supply Air Exhaust Air Design Difference Design Measured HP Note Exhaust Design Measured HP Airflow Airflow Name Airflow Airflow 3,525 3,900 3 Cold air CHE OGS-2 3,200 3,230 3 makeup air; RPM: 1,730 CHE ,800 2,570 11/4 4,800 1,750 11/4 Difference OGS-1 9,600 CHE ,270 11/4 004A-1 SSHE- 1,370 1,370 1/ FHE / Return Grill??? 1,190 Toatl CFM 16,325 7,130 14,890 9,850 1,435-2,720 Note: 1. Dp of mechanical room: WG (a maintenance door between outside air chase and the mechanical room was closed and kept return air grill open); 2. DP in Glass Shop: WG; 3. VFD of OGS-2: 100%; 4. Design information is before renovation; 4. Thermostats A room thermostat maintains the space temperature by modulating the amount of air from the VAV box and the heat coil valve in sequence. We checked each lab and office s thermostat. The findings are as follows: Problems Identified 35 of 150 thermostats were identified to be bad; At least 40 thermostats need to be calibrated; CC SM Measures Replaced 35 bad thermostats with new thermostats ordered; Calibrated 45 thermostats; IV. WHOLE BUILDING PRESSURE DISTRIBUTIONS 1. Introduction The building pressure distributions are not only related to energy savings, but also safety issues. The following exhaust and makeup air supply systems play a dominant role in whole building pressure distributions: The general exhaust systems consist of south chase, north chase and four exhaust fans (CEF-1, CEF-2, CEF-4 and CEF-5 on the roof) which exhaust airflow of 50 labs and offices through the south or north chases; 12

16 The central exhaust header systems consist of several heaters and four exhaust fans (EF-1, EF-3, EF-4 and EF-5 on the roof). The exhaust header systems exhaust all VAV airflow from the 12 big bench hoods and the 40 fume hoods on the second floor for VAV stable static pressure control. 85 CAV fume hoods receive makeup air supply from south chase or north chase and total exhaust airflow from these fume hoods are exhausted to the roof. Each of the 85 CAV fume hoods has its own exhaust fan on the roof. These 85 CAV fume hoods are in the labs in the basement, the third floor, the fourth floor and the fifth floor. The conditioned airflow from at least 70 VAV boxes from labs and offices; In order to solve extreme negative and positive DP problems for the labs we have tried to control or adjust the whole building pressure distributions. We did the following things: 2. Measured pressure distributions of labs, chases and hallways Measured DPs in W.G for all labs, different floor hallways, south chase and north chase. Table 4 and Table 5 show these measurements. Verified existing problems for each lab according to measured airflow data of all fume hoods, conditioned air flow from VAV boxes, bench exhaust and makeup systems. 3. Verification of DP transmitter for different exhaust fans Measured static pressure values and traced pneumatic control airlines; Verified 8 static pressure sensors for general exhaust systems (CEF-1, CEF-2, CEF-4 and CEF-5) and the central exhaust systems (EF-1, EF-3, EF-4 and EF-5) for VAV fume hoods and VAV bench hoods. 4. Calibrated DP Transmitters for the central heater exhaust systems and the general exhaust systems. Changed one bad or failed DP transmitter; Calibrated seven static pressure sensors; 5. Reset set points of static pressure for the central heater exhaust systems and the general exhaust systems. Measured lab DPs in Table 4 show that the DP values of each north side lab are larger than the required DPs and the DPs of each south side lab are less than the required. For the central heater duct systems, abnormal DP distributions are the same as above general exhaust system s DP distributions. The adjusted set points are as follows in Table 6. 13

17 Table 4: Measured Lab DPs in W.G with Respect to the Hallways and Outside North Chase South Chase Lab # Hallway to Lab Outside to Lab (Inch WG) Lab # Hallway to Lab Outside to Lab (Inch WG) ~ ~ ~ ~ ~ ~ ~ Outside air to hallway between Wing 72 and Wing 86: WG. 6. Problems The general exhaust systems and the central exhaust systems do not control the DP of all labs in the basement and on the fifth floor. They are related to makeup air supply from the south and north chase and exhaust to the roof. The DPs in these labs are far from the requirements (see Table 4). 14

18 7. Recommendations The final air balance for all labs in the basement and on the fifth floor: Measure lab DP again; If DP is extreme negative or positive, we will try to find the reasons (maybe dirty pre-heat coil, the fan RPM, belt and horse power of exhaust fan); Verify the DPs for all labs on the second floor, the third floor and the fourth floor; Table 5: Measured Chase DPs in W.G with Respect to the Hallways and Outside Lab # Outside to N. Chase (Inch WG) The Second Hallway Outside to S. Chase (Inch WG) Outside to Hallway (Inch WG) N. Chase to Hallway (Inch WG) S. Chase to Hallway (Inch WG) The Third Floor Hallway N. Chase The Fourth Hallway S. Chase The Fifth Floor ~ Hallway S. Chase 0.00 Table 6: Adjusted Set Points of Static Pressure for the Central Heater Exhaust Systems and General Exhaust Systems Exhaust Systems Central Heater Exhaust General Exhaust Exhaust fan number Direction Existing Set points (inches W.G.) EF-1 North Heater EF-3 South Heater EF-4 South Heater EF-5 South Heater CEF-1 North Chase CEF-2 North Chase CEF-4 South Chase CEF-5 South Chase Adjusted Set points (inches W.G.) 15

19 V. CHILLED WATER & HOT WATER SYSTEMS 1. The sequence of operations A Siemens Energy Management System is utilized for control of the four hot water pumps and two chilled water pumps. The sequence of operations is as follows: The hot water pump (HSHWP-1) for fume hood makeup air pre-heating coil will be energized at outside air temperature below 55ºF and de-energized at outside air temperature above 60ºF. The multiple zone hot water pump (MZHWP-1) will be energized whenever a multiple zone is energized and outside air temperature is below 65ºF. The supply water temperature will reset inversely with outside air temperature according to the following reset schedule: supply water temperature is 140ºF when outside air temperature is equal or less than 40ºF and supply water temperature is 100ºF when outside air temperature is equal or less than 70ºF. VAV hot water pump (VAVHWP-1) will be energized any time a VAV AHU is energized. Differential pressure sensor will control the speed of the pump to maintain the differential pressure at set point. Any time the pump is de-energized, the return valve will close. A sensor in the secondary supply line will, through the controller, maintain the supply water temperature by modulating the control valve on the primary return line. 2. Problems Identified VAV hot water pump (VAVHWP-1) is operating as a constant speed pump instead of being VFD controlled, due to the main part being repaired; Traced chilled water pipes to find chilled water DP sensors (building DP sensor and primary loop sensor) and verified the primary loop sensor for chilled water has wrong connection and that both sensors were bad. CHW loop balance could not be performed because the DP sensors are bad. The DP sensor is out of calibration at the low end. It shows DP of 22 psi when the actual DP is 11 psi. Both DP and actual psi show 34 psi when the pump is at full speed. Also, the DP sensor shows 11 psi when the actual DP is zero. 3. Recommendations The new CHW DP sensors need to be installed; The CHW loop balance needs be performed; Four hot water flow sensors need to be reinstalled and calibrated; We also need to take spring ranges on all the four HW return control valves and one CHW return control valve. The control programs for hot water pumps and chilled water pumps need to be modified; The water flow sensors cannot be calibrated until the following things are done for the Chemistry Complex, Wing 86. Pressure sensor range for primary loop and secondary loop of chilled water 16

20 We plan to install 6 individual pressure sensors to replace two bad existing differential pressure sensors. The locations and pressure ranges of these sensors are shown in Table 7. Pressure Sensor Name Primary Loop Secondary Loop (1) Secondary Loop (2) Sensor Number on Supply Pipe Table 7 Chilled Water Pressure Sensors Locations and Ranges Sensor Location Location Supply Return Number on Supply on Return Pressure Pressure on Pipe Pipe Range Range Return (psi) (psi) Pipe 1 1 Primary Supply Pipe (Before Pumps in the Basement) 1 1 Supply Secondary Pipe (After Pumps in the Basement) 1 1 Supply Secondary Pipe (On the Ceiling of the 6 th Floor by the East Top Stair) Primary Return Pipe (in the Basement) Return Secondary Pipe (in the Basement) Return Secondary Pipe (On the Ceiling of the 6 th Floor by the East Top Stair) Note 0~100 0~100 The Existing Chilled Water 0~125 0~125 0~50 0~50 Pump s Head: 100 ft; The building Height: 80 ft; Two of the four existing transmitters, which are old Robinson Halpern, for hot water flow sensors need to be replaced (see Table 8: Hot Water Flow Meter Data); Two of the four existing transmitters, which do not match their existing hot water flow meters, need to be changed (also see Table 8: Hot Water Flow Meter Data); Electronic wire connection between the transmitter and field control cabinet for each hot water pump is needed (also see Table 8: Hot Water Flow Meter Data); 17

21 Table 8 Hot Water Flow Meter Data Hot Water Pump Name HSHWP MAHWP VAVHWP-1 MZHWP Existing Transmitters Rosemount Factory mutual systems Max WP 2000 psi Supply 45 VDC Cal " H20 Serial # Output 4-20 ma Robinson Halpern Model 152CK270 Serial # Range psi Input VDC Output 4-20 ma Robinson Halpern Model 152CP015DS erial # Range psi Input VDC Output 4-20 ma Rosemount Factory Mutual System Max WP 2000 psi Supply 45 VDC Cal " H20 Serial # Output 4-20 ma Existing Flow meter 6"-743; " 3"-523; " 4" " 3" " Pump GPM Transmitters Suggested 300 GPM Rosemount Factory Mutual System Max WP 2000 psi Supply 45 VDC Cal " H20 Serial # Output 4-20 ma 76 GPM Rosemount Factory Mutual System Max WP 2000 psi Supply 45 VDC Cal " H20 Serial # Output 4-20 ma 200 GPM Rosemount Factory Mutual System Max WP 2000 psi Supply 45 VDC Cal " H20 Serial # Output 4-20 ma 100 GPM Rosemount Factory mutual systems Max WP 2000 psi Supply 45 VDC Cal " H20 Serial # Output 4-20 ma Things to Do 1. The Existing Transmitter (HSHWP) are Need to Exchange with the Transmitter of MZHWP Due to Their Differential Pressure Range 2. Electronic Wire Connection Between the Transmitter and Field Control Cabinet Is Needed 1. Order New Transmitter 2. Electronic Wire Connection Between the Transmitter and Field Control Cabinet Is Needed 1. Order New Transmitter 2. Electronic Wire Connection Between the Transmitter and Field Control Cabinet Is Needed 1. The Existing Transmitter (MZHWP) are Need to Exchange with the Transmitter of HSHWP Due to Their Differential Pressure Range 2. Electronic Wire Connection Between the Transmitter and Field Control Cabinet Is Needed 18

22 We have the information for two of the chilled water sensor transmitters, but we could not get the information about the chilled water flow sensors due to lost tags. We should use a different method to verify the existing chilled water flow meter tag information or verify them whether they are accurate or not. Table 9 shows the collected chilled water flow meter data. Chilled Water Pump Name CHW FX-1 Table 9 Chilled Water Flow Meter Data Existing Transmitters Rosemount Serial # Cal. 0-60" H20 Output 4-20 ma Supply 45 VDC max Max WP 2000 psi Existing Flow meter No info tag Pump GPM 1710 GPM Note CHW FX-2 Rosemount Serial # Cal. 0-60" H20 Output 4-20 ma Supply 45 VDC max Max WP 2000 GPM No info tag 1710 GPM 19

23 VI. COMPARISON OF PRE-CC SM AND POST-CC SM HOT WATER, CHILLED WATER AND ELECTRICITY CONSUMPTION 1. Continuous Commissioning SM activity periods are as follows: September 1998 November 1998: The fan speed control was changed to be based on static pressure setpoints rather than air flows; Replaced several bad pneumatic elements such as PXPs; Did airside measurements for most of theahus; December 1998 January 18, 2000: N/A January 18, 2000 July 15, 2000: Various CC SM activities mentioned in this CC SM report; Pre-CC SM and Post-CC SM periods: January 12, 1996 September 20, 1998 is used as the Pre-CC SM period; September 1998 January 18, 2000 is used as the first Post-CC SM period; January 18, 2000 July 15, 2000 is used as the second Post-CC SM period; 2. Measured data graphs (hot water, chilled water and whole building electricity for Pre-CC SM and Post-CC SM periods Measured hot water data, chilled water data and whole building electricity data were retrieved from the LoanSTAR database. The Emodel program is used to make measured data graphs for Pre-CC SM and Post-CC SM periods. Appendix G shows the following graphs: Whole building electricity vs. temperature grouped by Pre-CC SM and Post-CC SM periods; Chilled water vs. temperature grouped by Pre-CC SM and Post-CC SM periods; Hot water vs. temperature grouped by Pre-CC SM and Post-CC SM periods; The hot water vs. temperature graph grouped by Pre-CC SM and Post-CC SM periods include two buildings (Wing 72 and Wing 86) because one hot water meter has been monitoring these two buildings hot water consumption). 3. Comparison of Pre-CC SM and Post-CC SM periods These graphs shows that the energy consumption of hot water, chilled water and whole building electricity of Pre-CC SM is higher than one of the Post-CC SM periods. 4. Recommendations Develop baseline model Calculate savings 20

24 APPENDICES APPENDIX A. A COMPLETE LIST OF AIR HANDLERS AND THEIR SERVICES Table A 1. A Complete List of Air Handlers and Their Services AHU's VFD Makeup Cond. Rooms Notes Location OGS-1 x x 2204, AHUGS-1 x Glass shop Getting some outside air 2003 from duct that feeds OGS-2 OGS-2 x x Glass shop Not currently used 2003 OB-1 x x 2204, 2206, 2210, 2212 plenum that attaches B-1, -2 is in rm OB-2 x x 2204, 2206, 2210, 2212 " 2010 OB-3 x x 2213, OB-4 x x 2017(area in front of ele-) Supplies AHU-B1 w/ 2010 vators on base. Level), 2008, 2014, 2015, 2017B outside air OB-5 x x 2201, 2202, 2203, , 2215 bthrms, w. window and hallway in front of bthrm OB-6 x x 2204, 2206, 2210, and east window AHUB-1 x See Attach for Multz. Multizone 2010 AHU B-2 E Stairwell B Stairwell E AHU B-3 W Stairwell B Stairwell W AHUB-4 x 2119 AHU B AHU B A 2001A AHUB-7 x

25 Table A.2 A Complete List of Air Handlers and Their Services AHU's VFD Makeup Cond. Rooms Notes Location AHUG-1 x See Attach for Multz. Multizone AHUG-2 x See Attach for Multz. Multizone AHU2-1 x 2207 Suspended above AHU2-2 x 2208 Suspended above AHU2-3 x 2209 Suspended above AHU2-4 x 2219A Suspended above 2219A 2219A AHU2-5 x 2219B " " 2219B 2219B AHU2-6 x 2219C " " 2219C 2219C AHU3-1 x 2308 Suspended above AHU3-2 x 2311 Suspended above AHU3-3 x NE window facing street Level 3 AHU3-4 x NW window facing street Level 3 OAHU4-1 x x 2304, 2306 Makeup air for bench 2406 hoods; east side OAHU4-2 x x 2304, 2305, 2306, East side 2406 A, B, C, 2309, A, & East wind. On level 3 & Mid corridor on east side OAHU4-3 x x 2401, 2402, 2403, 2412, supplied outside air from , 2414, Midwest west penthouse hallway grill, west window, bthrms, and hallway by bthrms. OAHU4-4 x x 2301, 2302, 2303, 2310, supplied outside air from A,B,2312, 2312A west penthouse West window, bthrms. and hallway by bthrms. 22

26 Table A 1.3 A Complete List of Air Handlers and Their Services AHU's VFD Makeup Cond. Rooms Notes Location AHU4-1 x 2408 Suspended above AHU5-1 x 2512 Suspended above AHU5-2 x 2513 Suspended above AHU5-3 x 2514 Suspended above AHU5-4 x 2501 Suspended above AHU5-5 x 2502 Suspended above AHU5-6 x 2503 Suspended above AHU , 2408A 2408 AHU (Corridor) E 2406 AHU (Corridor) W 2415 OPH-1 x x 2404, 2405, 2407, 2409, East Pent. 2410, 2411, and East wind. On level 4 OPH-2 x x 2508, 2509, 2510, 2511, East Pent. 2515, 2516, 2517, 2518, 2519, 2520,2521, 2522, 2523, East window on level 5, and middle of corridor east. OPH-3 x x 2504, 2505, 2506, 2507, West Pent. 2524, 2525, 2526, 2527, 2528, 2529, middle of corridor west, west window in hall, hall by bthrm. and grill by double doors AHU PH-1 Elevator Machine Room Elevator Machine Room AHU L-1 Link to Wing 72 Link to Wing 72 AHU L-2 Link to Wing 72 Link to Wing 72 AHU L-3 Link to Wing 72 Link to Wing 72 23

27 APPENDIX B. HOT WATER PUMP INFORMATION Table B 1.1 Hot Water Pump Information Pump name SERVICE GPM TOTAL HEAD MOTOR DATA TYPE MIN. EFF. REMARKS SERVED LOCATION HSHWP-1 HOOD MAKEUP ' 7.5 HP, 460 V, 3PH, HORIZANTAL 75 HWP. DIST. ALL HOOD MAKEUP see location is HEATING COIL 60 HZ, 1750 RPM SPLIT CASE 3x4x10B 411 AURORA HEATING COILS attachment 2010 MAHWP-1 LAB. MAKEUP AIR 76 50' 3 HP, 460 V, 3 PH, HORIZANTAL 50 HWP DIST. OGS-1 & OGS location is UNIT REHEAT COILS 60 HZ, 1750 RPM SPLIT CASE 2x2.5x9 411 AURORA OB-1, OB-2, OB OAHU VAVHWP-1 LAB HEATING ' 7.5 HP, 460 V, 3 PH, HORIZANTAL 70 HWP. DIST. ALL VAV BOXES see location is COILS 60 HZ, 1750 RPM SPLIT CASE 2.5x3x10B 411 AURORA attachment 2010 MZHWP-1 MULTIZONE ' 3 HP, 460 V, 3 PH, HORIZANTAL 60 HWP. DIST. AHU B location is HEAT PUMP 60 HZ, 1750 RPM SPLIT CASE 2x2.5x AURORA AHU G AHU G

28 Table B 1. Two Hot Water Pumps (VAVHWP-1 and HSHWP-1) Serve the VAV Boxes and Fume Hoods in Different Labs What the hot water pump, VAVHWP-1 serves: What the hot water pump, HSHWP-1 serves. Room # Description # of VAV Room # Description # of Fume hoods Stck. Rm Stck. Rm office office 2202A flammable 2202A flammable preparation rm preparation rm Red Lab Red Lab. 3 BFH; 3FH 2205 research research Green Lab Green Lab. 3 BFH; 3FH 2210 Organic Chem Organic Chem. 3 DBFH; 3FH 2211 office 2211 office 2211E Insrument rm E Insrument rm research research 3DBFH; 3FH 2213 yellow lab yellow lab 3 BFH; 3FH 2214 Insrument rm Insrument rm blue lab blue lab 3 BFH; 3FH 2219A office 2219A office 2219B office 2219B office 2219C office 2219C office 2301 Stck. Rm Stck. Rm electro chem electro chem research research General chem General chem. 3BFH; 2FH 2305 instrument rm instrument rm 2306 Quantitative an Quantitative an research research A office 2307A office 2307B office 2307B office 2308 computer rm 2308 computer rm 2309A instrument rm 2309A instrument rm 2309 analytical chem analytical chem analytical chem analytical chem A office 2310A office 2310B instrument rm 2310B instrument rm 2311 office 2311 office 2311A office 2311A office 2311B office 2311B office 2311C brkrm 2311C brkrm 2312 research research 6 3BFH; 2FH 25

29 Table B 2 Two Hot Water Pumps (VAVHWP-1 and HSHWP-1) Serve the VAV Boxes and Fume Hoods in Different Labs Room # Description # of VAV Room # Description # of Fume hoods 2312A instrument rm 2312A instrument rm 1 "small" 2401 Stck.rm Stck.rm Nuclear chem Nuclear chem Radio chem Radio chem instrument rm instrument rm 2405 Adv. Inor Adv. Inor. 4 Chem Chem 2407 xray diffraction xray diffraction office 2408 office 2409 physical chem physical chem instrument rm instrument rm physical chem physical chem physical chem physical chem preparation rm preparation rm preparation rm preparation rm mechanical 2415 mechanical 2504 research research research research * not occupied * not occupied * not occupied * not occupied research research research research research research research research office 2512 office office 2515 office 2516 instrument rm instrument rm instrument rm instrument rm office 2518 office 2519 research research research research research research research research research research research research research research research research office 2527 office 2528 instrument rm 2528 instrument rm 2529 instrument rm 2529 instrument rm 2530 office 2530 office 26

30 APPENDIX C. 86 WING FH SUPPLY MOTOR REPLACEMENT SCHEDULE Table C.1 Fume Hood Supply Motor Replacement Room Model of Motor Location Served HP RPM 2214 PP17607 South Chase F. Hood 1 HP 1750 RPM 2nd Flr PP17627 North Chase F. Hood 1/2 HP 1750 RPM 2nd Flr PP17610 South Chase F. Hood #3 1 HP 1750 RPM 3rd Flr PP17645 South Chase F. Hood #1 1 HP 1750 RPM 3rd Flr. old 2312 PP17651 South Chase F. Hood #3 1 HP 1750 RPM 4th Flr. old 2413 PP17649 South Chase F. Hood #1 1 HP 1750 RPM 4th Flr. old 2526 PP17648 South Chase F. Hood #1 1 HP 1750 RPM 4th Flr. old 2412 PP17647 South Chase F. Hood #2 1 HP 1750 RPM 4th Flr. old 2525 PP17646 South Chase F. Hood #1 1 HP 1750 RPM 4th Flr. old 2310 PP17644 South Chase F. Hood #2 1 HP 1750 RPM 4th Flr. old 2309 PP17642 South Chase F. Hood #3 1 HP 1750 RPM 4th Flr. old 2411 PP17641 South Chase F. Hood #1 1 HP 1750 RPM 4th Flr. old 27

31 Table C.2 Fume Hood Supply Motor Replacement Room Model of Motor Location Served HP RPM 2410 PP17640 South Chase F. Hood #1 1 HP 1750 RPM 4th Flr. old 2409 PP17639 South Chase F. Hood #2 1 HP 1750 RPM 4th Flr. old 2409 PP17637 South Chase F. Hood #1 1 HP 1750 RPM 4th Flr. old 2524 PP17662 South Chase F. Hood #4 1 HP 1750 RPM 5th Flr PP17666 South Chase F. Hood #4 1 HP 1750 RPM 5th Flr. old 2523 PP17667 South Chase F. Hood #1 1HP 1750 RPM 5th Flr. old 2522 PP17668 South Chase F. Hood #1 1 HP 1750 RPM 5th Flr. old 2521 PP17672 South Chase F. Hood #1 1 HP 1750 RPM 5th Flr. old 2520 PP17674 South Chase F. Hood #1 1 HP 1750 RPM 5th Flr. old 2519 PP17577 South Chase F. Hood #1 1 HP 1750 RPM 5th Flr. old 2519 PP17679 South Chase F. Hood #3 1 HP 1750 RPM 5th Flr. old 2518 PP17680 South Chase F. Hood #1 1/2 HP 1750 RPM 5th Flr. old 2517 PP17681 South Chase F. Hood #1 1/2 HP 1750 RPM 5th Flr. old 2204 PP17--- North Chase F. Hood #1 1 HP 1750 RPM 3rd Flr. old 2401 PP17701 North Chase F. Hood #1 3/4 HP 1750 RPM 4th Flr. old 28

32 APPENDIX D. DESIGN LAB AIR BALANCE INFORMATION Table D.1 Design Lab Air Balance Information Lab. Supply Air Exhaust Air Lab. Air Balance Number VAV Pri. Air Max.Vol. MakeUp Air Vol. DFHS Vol. FHS Vol. DFHE Vol. FHE Vol. BFHE Vol. Total Supply Total Exhaust Diffrence / A * / * * /900* * * * * /900* * * * * / /1050* * * * * * /1050* * * * * * /1050* * * * * /1050* * * * * / / / * * / * * / * * / / * * / A B A / * * / * * A A B / * *

33 Table D.2 Design Lab Air Balance Information Lab. Supply Air Exhaust Air Lab. Air Balance Number VAV Pri. Air Max.Vol. MakeUp Air Vol. DFHS Vol. FHS Vol. DFHE Vol. FHE Vol. BFHE Vol. Total Supply Total Exhaust Diffrence / / / * * / / * * / * * / * * / / * * / * * / / / * * / * * / * * / * * / * * / * * / * * / * * / / / * * / * * / * * / * * / * * / * * / * * / / * *

34 APPENDIX E. TROUBLESHOOTING REPORTS FOR DIFFERENT LABS ON DIFFERENT DATA 1. Troubleshooting for Lab 2206 (February 21, 2000) Complaint: Lab 2206 is too humid and cold What we found: Room conditions: Temperature is 64ºF; Humidity is 72%. Super saturated with "high humidity". The tile floors became extremely slippery on February 16, Discharge temperature of two AHUs: OB-6 (supply cool air to VAV box of this lab): 61ºF; OGS-1 (makeup air to the lab): 55ºF; Reheat control valve of OGS-1 was commanded to fully closed; Makeup hot water pump was off; Wrong electronic wire connection between two controllers and reheat control valves of lab 2206; Pneumatic air pressure to makeup air controller and VAV controller was 17 psi and old pneumatic air line (old control devices were used before renovation in 1995) pressure to these controllers was 23 psi; A booster pump for pre-heat coil shared same point name of control with outside air damper of OGS-1; The reasons for high humidity and low temperature in the lab: The high humidity was caused by a chilled water valve "sticking" and not obeying the control command. This caused the coil temperature to rise above the dew point and stop dehumidifying. Hot water difference pressure was not good enough; What we did: The sticky chilled water valve of OB-6 was moved by a different command from Apogee and different pressure by means of Squeeze Ball. The discharge temperature was decreased to 56ºF. Fully opened the reheat control valve of OGS-1 and then supply makeup air temperature was increase from 55ºF to 70ºF. A new 17 psi pneumatic air line was connected to old pneumatic air line (23 psi) in order make sure there was enough compressed air pressure for two controllers; Old pneumatic air line and devices which are useless were removed; Things to do for lab 2206 An electronic wire for the booster pump and outside air damper of OGS-1 is needed to separate into two lines in field panel; The PPCL control program for OGS-1 is needs to be modified. 31

35 The VAV damper and makeup air damper are needed to adjust for lab air balance. Homer has ed the following things to Area Maintenance II: The 1/4" hardware cloth behind the outside air intake louvers to AHU-OGS1 in the basement of the 86'wing is extremely clogged. The belts to the AHU were very loose and we tightened them. The air filter need to be changed ASAP and the pre-heat coil needs to be cleaned. Also the hot water make up pump MAHW needs to be checked, it makes a very loud noise when turned on. All coils need to be cleaned and all filters in the 86 Wing need to be changed. 2. Troubleshooting for Lab 2213 (February 21, 2000) Complaint: Lab 2213 is too hot What we found: Room conditions: Temperature is 81.5ºF; Humidity is 62%. Supply air temperature from different diffusers for two AHUs on February 18, 2000: Air temperature from round diffuser which is related to OB-6 (supply cool air to VAV box of this lab): 95ºF; Air temperature from line slot diffuser which is related to OB-2 (makeup air to the lab): 70ºF; Electronic power which interlocks to the makeup air controller, VAV controller and reheat control valves of lab 2213 was broken on February 16, 2000; Reheat control valves of two VAV boxes were not removed by different command to Terminal Electronic Controller (TEC) after electronic power came back to TECs; Reheat coils of two VAV boxes in lab 2213 were working; Makeup air damper (NC ) range was identified to be 4 15 psi and the signal pressure from makeup air TEC was only 11 psi. This damper only moved from 0 % to 50 % (open); Pneumatic air pressure to makeup air controller and VAV controller was 9-11 psi and old pneumatic air line (old control devices were used before renovation in 1995) pressure to these controller was 20 psi on February 18, 2000; Two possible reasons for high temperature in the lab: Wrong electronic wire connection between TECs and reheat control valves of lab 2213; Reheat control valves are sticky; What we did: Temporarily turned off two manual hot water valves for two reheat coils; 32

36 9-11 psi new pneumatic air line was disconnected and old pneumatic air line (20 psi) was connected to two controllers in order make sure there was enough compressed air pressure for two controllers; Things to do for lab 2213 The dampers in two VAV boxes need to be adjusted for air balance ffor lab 2213; Continue to verify the reason for wrong control of lab Troubleshooting 2504 (March 3, 2000) Complaint: A professor told me his office was hot (85ºF) when I was ready to leave 5 th floor at 5:20 p.m. last Friday. What I found Thermostat was disconnected and airline to thermostat was too bad to use; What I did I got a new thermostat and a soft rubber airline from my office, and two Area Maintenance II workers came to do the change out. 4. Troubleshooting for lab 2520, 2519 and 2119 (March 24, 2000). The following is troubleshooting information for lab 2520, 2519 and An OAHU PH-2 in the east Penthouse, Wing 86 of the Chemistry Complex, supply cooling air (the discharge temperature setpoint is 55ºF) to 9 labs which included 2520 and For each lab, there is a reheat coil and a VAV damper to control lab conditions. Lab 2520 What we found: Lab 2520 conditions: Lab temperature is 60ºF; Supply air temperature from diffusers is 51.2ºF; The discharge temperature of OAHU PH-2 is 49.97ºF; Manual hot water valves on supply and return sides were off; No signal from lab thermostat even though setpoint value was changed and calibration screw was adjusted; Supply air temperature from diffusers is 60ºF after an existing thermostat was changed and two hot manual values were turned on What we did: Installed new thermostat for the lab; Turned on two manual valves on supply and return hot water sides; Different values were given to chilled water valve (NC), but the valve still maintains fully open position (the discharge temperature remains 49.97ºF); 33

37 Recommendation: The signal pressure range from the controller on the board (SCU # 14) to the chilled water valve is 17 ~ 22 psi when I gave different values (1 ~ 18) to the chilled water valve. The range (17 ~ 22 psi) keeps the chilled water valve wide open. We need a Simen employee to come to the east Penthouse to solve the control problem for OAHU PH-2 within the next week. Lab 2519 What we found: Lab 2519 conditions: Lab temperature is 68.5ºF; Supply air temperature from diffusers is 62.2ºF; The discharge temperature of OAHU PH-2 is 49.97ºF; No signal from lab thermostat even though setpoint value was changed and calibration screw was adjusted; What we did: Installed new thermostat for the lab; Different values were given to chilled water valve (NC), but the valves remains in fully open position; Current lab 2519 condition: Lab temperature is 69.5ºF; RH: 47 % Recommendation: Same as the above recommendation ffor lab Lab 2119 What we found: Lab 2119 conditions: Lab temperature is 89.5ºF; What we did: Calibrated a thermostat for the lab; Current lab 2519 condition: Lab temperature is 71ºF; 5. Troubleshooting for Room 2103 (March 31, 2000) Room 2103 is a video, projection equipment room. An AHU-G2 (multiple-zones) serves the room (called zone 4). A thermostat that is related to the zone heating coil in the room controls room conditions. Complaint: 34

38 David, who is in charge of chemical instruments and equipment for this department, told me the room was hot about two weeks ago even though the room thermostat had been adjusted to 60ºF set point. He said that Harry, Area Maintenance II, told him this hot room problem is related to programming and he could not do it. What I found: Room temperature was 78.4ºF and humidity level was 54%; Zone heating coil was On although the signal air from the room thermostat showed it should be shut off (15 psi for the NO control valve) Reason: Control air in the Positioning Relay of the heating valve was leaking; What I did: Turned off two hot water manual valves; Recommendation: Have someone else repair the control air leakage problem as soon as possible. 6. Zone 5 of AHU-G2 (March 31, 2000) What I found: The supply air duct in zone 5, AHU-G2 in room 2123, has extreme leakage. It is obvious that someone cut the supply air duct to fix some problem inside and the person did not get a big enough metal area to cover the cut supply air duct area, which left a right-angled triangle with sides 3" by 5" (estimated leakage area size) open. Recommendation: The leakage problem needs to be fixed as soon as possible. 7. Troubleshooting for lab 2119 (March 31, 2000) What we found: Lab temperature was 83.5ºF even though two doors were opened. Cover of thermostat was removed. Sensitivity slide of the thermostat was broken Control air in the thermostat was leaking Reason: It is obvious that someone damaged the thermostat after we calibrated the thermostat on March 21, What we did: Install new thermostat, the existing thermostat was to damaged to calibrate. Current lab 2119 condition: Room temperature is close 72ºF. 35

39 8. Troubleshooting Noise in Labs 2310 and 2312 (June 2, 2000) Labs 2310 and 2312 are chemical labs. There are 3 variable air volume fume hoods and 3 constant air volume fume hoods. A variable air volume box supplies cooling air to each lab. Two general exhaust grills exhaust lab air to the roof. In lab 2312, there are 4 vacuum pumps and 1 oil mist filter and 1 coolflow refrigerated recirculator. Complaint: Too much noise in these two labs; What I found: 6 fume hoods making noise; Four vacuum pumps, one oil mist fitter and 1 coolflow refrigerated recirculator also contribute to the noise level. The total makeup air flow and exhaust air flow of 12 fume hoods in these two labs are at the normal range which is close to design conditions; The noise level is not only from 6 fume hoods but also from some machines in each lab. It is a combination noise. What I did: Measured total makeup air flow and exhaust air flow for a total of 12 fume hoods; Things to do (at occupants requests): We need to get decibel readings in the labs over an extended period of time. Then we can do this in a number of other labs that are cited as being noisy. Armed with these data, we can decide what to do. 9. Troubleshooting for lab 2206 (June 9, 2000) The lab 2206 is a big chemical research and teaching lab. There are 3 VAV fume hoods and 3 bench hoods. The 2 VAV terminal reheat boxes supply conditioned air and the linear slot diffusers supply makeup air to the lab. At the AHUs level, OGS-1 supplies makeup air and OB-6 supplies cold air to the lab. Complaint: Lab 2206 is too cold What we found: Room conditions: Temperature is 60ºF; Humidity is 50%. Discharge temperature of two AHUs: OB-6 (supply cool air to VAV box of this lab): 55ºF; OGS-1 (makeup air to the lab): 57ºF; Hot water pump (MAHWP-1) was off; No hot water was available in the lab reheat coil because the other hot water pump (VAVHWP-1) was also turned off (disassembled); The reason for low temperature in the lab: Hot water supply is not available to both OGS-1 and terminal VAV-reheat boxes; 36

40 Recommendation Two hot water pumps (MAHWP-1 and VAVHWP-1) are also related to several AHUs and labs so the two pumps need to be on ASAP. 37

41 C H senoz 7f o l a ic p y T 4 D C C C 3 A M n a F ly p p u S 2 A R 1 A O APPENDIX F. Airside Measurement of AHUs AHU G -1 Location Temperature ( F) Duct Size (in) Velocity (fpm) Flow Volume Design X Zones Before/After RH (T) Static Before/After Duct Size (in) Velocity Flow Volume Design (fpm) Z Z Z Z Z Z Z Area Served (ft 2 ) 38

42 C H senoz 7f o l a ic p y T 5 D C C C 4 A M n a F ly p p u S 3 2 A R 1 A O A R AHU G-2 (CD bypass) Location Temperature ( F) Duct Size (in) Velocity (fpm) Flow Volume Design 1 (OA) X (RA) X (RA) 8 X (MA) (CD) Before/After RH ( T) Static Before/After (in WC) Duct Size (in) Flow Volume Velocity Zones (fpm) Z Z Z Z Z Z Z Design Area Served (ft 2 ) 39

43 C H senoz 7f o l a ic p y T 4 D C C C 3 A M n a F ly p p u S 2 A R 1 A O AH U B-1(multizone, CD bypass) Location Temperature ( F) Duct Size (in) Velocity (fpm) Flow Volume Design 1 (OA) X (RA) X / (MA) (CD) Zones Before/After RH ( F) Static Before/After (in WC) Flow Volume Duct Size (in) Velocity (fpm) Z Z Z Z Z Design Area Served (ft 2 ) 40

44 C H senoz 7f o l a ic p y T 5 D C C C 4 A M n a F ly p p u S 3 2 A R 1 A O A R AHU B-4 (multizone, CD bypass) Location Temperature ( F) Duct Size (in) Velocity (fpm) Flow Volume Design 1 (OA) (RA) X (RA) X (MA) (CD) 54.7 Zones Before/After RH ( F) Static Before/After (in WC) Z Z Z Duct Size (in) Velocity (fpm) Flow Volume Design Area Served (ft 2 ) 41

45 1 OB-1 A O 4 n a F ly p p u S H R 3 C C 2 H P Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X /4100 note: 7.5 horsepower motor with VFD 42

46 1 OB-2 A O 4 n a F ly p p u S H R 3 C C 2 H P Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design (2 min) X /5520 note: 10 Hp motor with VFD (85%) 43

47 1 OB-6 A O 4 n a F ly p p u S H R 3 C C 2 H P Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design Not Able ? 11130/4735 note: Hz, VFD (70%) 44

48 4 n a F ly p p u S H R 3 C C 2 H P 1 A O OAHU-B3 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design (1 min) (1 min) X /5280 note: 45

49 3 n a F ly p p u S C C 2 H P 1 A O OAHU-B4 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X /1700 note: 46

50 3 n a F ly p p u S C C 2 H P 1 A O OAHU-B5 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X ? /6500 note: 1. Supply to PH is hot & too close to be measured 47

51 4 n a F ly p p u S 3 C C 2 H P 1 A AHU-B7 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X note: 1. Can t measure Location 2, but PH water is known to be shut off. 48

52 5 a F ly p p u S 4 3 D C C C 2 1 A R A AHU-GS-1 n H D H C Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocit y (fpm) Flow Volume Design X x

53 3 n a F ly p p u S C C 2 H P 1 A O OAHU-GS-1 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X /4800 note: 1. VFD (63%) 50

54 5 n a F ly 4 p p u S H R 3 C C 2 H P 1 A O OAHU-GS-2 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X

55 5 n a F ly 4 p p u S H R 3 C C 2 H P 1 A O OAHU 4-1 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X ~ x /

56 4 n a F ly p p u S 3 C C 2 H P 1 A O OAHU 4-2 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design x /

57 4 n a F ly p p u S 3 C C 2 H P 1 A O OAHU 4-3 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design x X /5890 Note: PH is off 54

58 4 n a F ly p p u S 3 C C 2 H P 1 A O OAHU 4-4 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design x X /

59 4 n a F ly p p u S 3 C C 2 H P 1 A O OAPH-1 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X /

60 4 n a F ly p p u S 3 C C 2 H P 1 A O OAPH-2 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X x /

61 4 n a F ly p p u S 3 C C 2 H P 1 A O OAPH-3 Location Temperature ( F) Pressure (in WC) Duct Size (in) Velocity (fpm) Flow Volume Design X84 830/ off /

62 APPENDIX G. ELECTRICITY, CHILLED WATER AND HOT WATER CONSUMPTION vs. TEMPERATURE GROUP BY PRE-CC SM /POST-CC SM 1. Electricity Consumption Figure 1: Electricity Consumption --- Pre-CC SM is chosen during the period of January 12, 1996 September 20, 1998; ο---the First Post-CC SM is chosen during the period of September 1998 January 18, 2000; --- The Second Post-CC SM is chosen during the period of January 18, 2000 July 15, 2000; 2. Chilled Water Consumption Figure 2: Chilled Water Consumption --- Pre-CC SM is chosen during the period of January 12, 1996 September 20, 1998; ---The First Post-CC SM is chosen during the period of September 1998 January 18, 2000; --- The Second Post-CC SM is chosen during the period of January 18, 2000 July 15, 2000; 59

63 3. Hot Water Consumption Figure 3: Hot Water Consumption X--- Pre-CC SM is chosen during the period of January 12, 1996 September 20, 1998; ο---the First Post-CC SM is chosen during the period of September 1998 January 18, 2000 (measured hot water data missing); --- The Second Post-CC SM is chosen during the period of January 18, 2000 July 15, 2000; The Hot water vs. temperature graph grouped by Pre-CC SM and Post-CC SM periods includes two buildings (Wing 72 and Wing 86) because one hot water meter has been monitoring these two building hot water consumption). 60