Overview of LBNL’s High-Tech Buildings Project Activities Bill Tschudi and Tim Xu April 21, 2004...

Overview of LBNL’s High-Tech Buildings

Project Activities

Bill Tschudi and Tim Xu

April 21, 2004WFTschudi@lbl.govTTXu@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

wftschudi@lbl.gov ttxu@lbl.gov

510-495-2417 510-486-7810

Website: http://ateam.lbl.gov