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Page 107
Today’s Agenda
• Welcome and Introductions• Introduction to Smart Labs• Prerequisites for Smart Labs• Lighting• Mechanical System• Determining the Potential for Air Change Reductions• Centralized Demand Controlled Ventilation• ANSI Z9.5 2012• Exhaust Stack Discharge Volume Reduction• Dashboard and Energy Savings• Constant Commissioning and Return on Investment• Conclusion and Wrap-Up• Questions and Answers
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AIHA / ANSI Z9.5 2012 Standard for Laboratory Ventilation Published September 2012
Minimum requirements and best practices
Supports OSHA Chemical Hygiene Plan and Hazard Assessment
Requires lab ventilation management program
Specifications for new and renovated laboratories
Hood design and operation
Laboratory design
Ventilation system design
Commissioning and routine testing
Work practices and training
Preventative maintenance
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Laboratory Ventilation Management Plan (LVMP)
“Management shall establish a Laboratory Ventilation Plan (LVMP) to ensure the proper selection, operation, use, and maintenance of laboratory ventilation equipment.”
1. Commissioning to verify proper performance and use2. Description of training programs for proper use, maintenance,
and testing of lab hoods3. Design of Ventilation Systems4. Maintenance procedures for providing and documenting
reliable operation5. Specifications of monitors to continuously verify proper
operation of the lab hoods6. Standard Procedures for routine testing
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UC Irvine Minimum Safe Fume Hood Air Flow Study
• Another opportunity to reduce energy use in labs is by minimizing the exhaust flow through VAV fume hoods when the sash is closed
• Study to balance safety and energy conservation
• Our goal was to determine the minimum safe exhaust flow for VAV hoods in fume hood driven labs
• By Exposure Control Technologies, Inc. and Safelab Corporation
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UC Irvine Minimum Safe Fume Hood Air Flow Study
• Can exhaust flow can be safely reduced below current design flow ?
• The new ANSI Z9.5 Standard recommends basing the minimum fume hood air flow on the internal volume of the fume hood and internal air change per hour (ACH)
• 375 ACH is roughly equivalent to 25 cfm/ft2 and 150 ACH is roughly equivalent to 10 cfm/ft2
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UC Irvine Minimum Safe Fume Hood Air Flow Study
Safety Considerations:• The processes and materials
generated within the hoods• Hood containment and
dilution of hazardous concentrations within the hood
• Potential for increased corrosion
• Effect on air duct transport and stack discharge velocities
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Reduced Fume Hood Air Flow Study Results Table
5ft hood cfm ACH Evaporation Rate limit
Chemicals
Current Design Minimum
250 375 n/a n/a
New Design Minimum
167 250 Less than1.2 lpm
*
Possible New Design
Minimum
133 200 Less than 1.2 lpm
*
*Any chemical with LEL >1%(10,000 ppm or higher)
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Reduced Fume Hood Air Flow Study Results Table
*Any chemical with LEL > 1%(10,000 ppm or higher)
6ft hood cfm ACH Evaporation Rate limit
Chemicals
Current Design
Minimum
313 375 n/a n/a
New Design Minimum
208 250 Less than 1.5 lpm
*
Possible New Design
Minimum
167 200 Less than 1.5 lpm
*
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Reduced Fume Hood Air Flow StudyEnergy Savings
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Today’s Agenda
• Welcome and Introductions• Introduction to Smart Labs• Prerequisites for Smart Labs• Lighting• Mechanical System• Determining the Potential for Air Change Reductions• Centralized Demand Controlled Ventilation• ANSI Z9.5 2012• Exhaust Stack Discharge Volume Reduction• Dashboard and Energy Savings• Constant Commissioning and Return on Investment• Conclusion and Wrap-Up• Questions and Answers
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JUST SAY NO TO BYPASS AIRExhaust Stack Discharge Volume Reduction
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Exhaust Stack Discharge Volume Reduction (ESDVR)
What is bypass and how much energy is wasted?
If so much energy is wasted, what can we do about it?
Steps in the wind-tunnel study process
Stack extensions
Other implementation results
Next steps: wind-responsive controls
Participatory exercise
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What is a bypass?
The bypass brings outside air from the roof through the fan to ensure design velocity out the top of the stack regardless of flow through the building, thus creating a constant-volume system out of a variable-volume system and wasting energy.
This is a High‐Plume Discharge Fan. Bypasses are also fitted to systems with other types of fans.
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Why have a bypass?
• Allows the system to operate safely and maintain a minimum velocity of discharge to ensure that the plume of air rises up sufficiently to avoid re-entrainment to the building or contamination of adjacent buildings.
• Allows constant-speed and volume fans to work with variable-volume flow from the building
• Provides a simple means of controlling static pressure in the exhaust system
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Lab Exhaust Diagram
Peak Wind
Exhaust FanBypass Damper
Plenum
Fume Hood Building Air Intake
Balcony
3500
FPM
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How much energy is wasted?
• If building flow is 25,000 cfm and required flow from the stack to attain 3,500 fpm is 50,000 cfm, the energy wasted is 50%, at a minimum.
• By reducing the flow in the stack one also reduces the pressure drop in the stack and therefore the effect on energy savings is compounded. Reduced area “shooters” or discharge nozzles typically have much greater losses than expected.
• Each situation is specific to the site.
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If so much energy is wasted,what can we do about it?
• Modeling the building in a wind tunnel to determine the minimum exhaust velocity required with a reasonable stack height instead of selecting the shortest stack possible based on a fairly high velocity
• Install variable-speed drives to control system static pressure
• Program control system to run multiple fans in parallel with a goalof 0% bypass
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One can’t just close bypass and turn down exhaust volume.
Re-entrainment at balcony
2000
-250
0 FP
M
What about closing bypass andletting fans “ride the curve”?
Peak Wind
Building air intake
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Increasestack height
2000-2500 FPM
What about raising stack height?
Peak Wind
2000-2500 FPM
Bypass closed
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Steps in the wind-tunnel study process
1. Build model of campus
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Steps in the wind-tunnel study process
1. Build model of campus2. Install model stacks
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Steps in the wind-tunnel study process
1. Build model of campus2. Install model stacks
3. Install air sampling points (“receptors”)
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Flow Visualization Natural Sciences 1
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Flow Visualization Natural Sciences 1
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Stack Extensions
1. Extraordinary savings1. Small costs up front
2. Passive system that has no maintenance costs
3. Reduced fan energy in one case by 78%
2. But what about the “ugliness” factor?
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The Ugliness Non-Factor: Before
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The Ugliness Non-Factor: After
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Will stack extensions impact the campus architecture?
One of the biggest challenges to raising the stack heights is how will this impact the look of the campus.
UCI completed the following visual simulations prior to the construction. These renderings were provided to the Design Review Team.
To date no one on campus has noticed, or provided negative feedback.
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Natural Sciences I - Existing
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Natural Sciences IProposed 4-Foot Extension
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Natural Sciences I - Existing
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Natural Sciences IProposed 4-Foot Extension
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Natural Sciences II - Existing
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Natural Sciences IIProposed 4-Foot Extension
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Natural Sciences II - Existing
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Natural Sciences II – Proposed 4-Foot Extension
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Croul Hall - Existing
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Croul Hall – Proposed 8-Foot Extension
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McGaugh Hall Stack Extensions
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McGaugh Hall Stack Extensions
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Implementation
• Install variable frequency drives (VFD)
• Closed bypass dampers
• No stack extension
• Annual energy savings:
580,000 kWh
Sprague Hall
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Implementation
• Install variable frequency drives (VFD)
• Static pressure reset
• 4’ stack extensions
• Annual energy savings:
928,000 kWh
Natural Sciences II
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Implementation
• No stack extensions
• Install variable frequency drives (VFD)
• Static pressure reset
• Annual energy savings:
287,000 kWh
Hewitt Hall
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Install anemometer 2000-2500 FPM
Peak Wind
Can we do better?
2000-2500 FPM
Bypass closed or openIf building flow insufficient to providevelocity needed
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No Wind
Install anemometer
1500-2000 FPM
Can we do better?
Bypass closed until fans at minimum speed, then throttleAs needed to maintain static pressure
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Typical Design Flow
New Wind Tunnel Design Flow
Required For Dispersion
Required by High Air Change Rate
Required by Low Air Change Rate
ESDVR Savings Without Wind SensingESDVR Energy Savings With Wind Sensing
Typical TimelineExit Velocity Requirements
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Break for Lunch
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Today’s Agenda
• Welcome and Introductions• Introduction to Smart Labs• Prerequisites for Smart Labs• Lighting• Mechanical System• Determining the Potential for Air Change Reductions• Centralized Demand Controlled Ventilation• ANSI Z9.5 2012• Exhaust Stack Discharge Volume Reduction• Dashboard and Energy Savings• Constant Commissioning and Return on Investment• Conclusion and Wrap-Up• Questions and Answers
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• Air change rates (ACR)• Internal air quality (IAQ)• Sash position of each fume hood• Occupancy• Relative humidity• Temperature• Total supply• Total exhaust
CDCV SystemDashboard and Data Trends for Each Zone
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Visualization of lab HVAC use
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Visualization of lab HVAC useto determine what is driving ACH
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• Fume hood usage range• This hood shows usage between 0%
open and 65% open.
• Change in average sash position from the month prior• Red indicates poorer average green indicates improved
average sash management
Monitoring Fume Hood Usage
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Smart Labs are not just controls and sensors.
Smart Labs provide real time feedback as well as monthly reporting data that is actionable.
Return on investment is directly affected by lab practices.
How many hoods are in use right now in your laband how far open are the sashes?
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Total Flow and ACH ProfileSix-Day Period
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Air Change Rates for Room 1200Graphed Over Six Days
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The delta between 6 air changes per hour in previous labs designs and the 4/2 ACHof Gross Hall is yielding ~$58,000 per year in energy savings.
What does energy savings look like?
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Trending occupancy sensors to normalize energy consumption data
0%
20%
40%
60%
80%
100%
Gross Hall Hewitt Hall
58%27%
Percent Occupied by Building (7 days)
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‐
1.00
2.00
3.00
4.00
5.00
6.00
0:15
1:00
1:45
2:30
3:15
4:00
4:45
5:30
6:15
7:00
7:45
8:30
9:15
10:00
10:45
11:30
12:15
13:00
13:45
14:30
15:15
16:00
16:45
17:30
18:15
19:00
19:45
20:30
21:15
22:00
22:45
23:30
Watts per Square Foot
Time of Day
Watts / Gross Square Foot
Hewitt Hall
Gross Hall
Building Load Per Square Foot
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AHU + EF + Pumps + Chilled WaterBuilding Square Feet
0
1
2
3
4
5
60:15
0:45
1:15
1:45
2:15
2:45
3:15
3:45
4:15
4:45
5:15
5:45
6:15
6:45
7:15
7:45
8:15
8:45
9:15
9:45
10:15
10:45
11:15
11:45
12:15
12:45
13:15
13:45
14:15
14:45
15:15
15:45
16:15
16:45
17:15
17:45
18:15
18:45
19:15
19:45
20:15
20:45
21:15
21:45
22:15
22:45
23:15
23:45
Watts per Square foot
Hewitt Hall Gross Hall Gross Total Building Hewitt Hall Total Building
1 Watt /1000 x 8760 hours x $0.105kWh= $0.92 /SqFt
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Previous Best Practice
Space Type Gross
Hall
0.9 watts/sqft Offices
0.49 watts/sqft
1.1 watts/sqft Labs
0.66 watts/sqft
1 watts/sqft Overall Conditioned Space
0.61 watts/sqft
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0:15
1:30
2:45
4:00
5:15
6:30
7:45
9:00
10:15
11:30
12:45
14:00
15:15
16:30
17:45
19:00
20:15
21:30
22:45
0:00
Watts Per Square Foot
24 Hour Actual Watts Per SQFT
Hewitt Hall Watts Per Sqft Gross Hall Watts Per Sqft
0
2
4
6
8
10
12
14
16
18
20
0:15
1:15
2:15
3:15
4:15
5:15
6:15
7:15
8:15
9:15
10:15
11:15
12:15
13:15
14:15
15:15
16:15
17:15
18:15
19:15
20:15
21:15
22:15
23:15
kW
24 Hour Demand Curves
Hewitt Hall 2nd Floor Lighting Demand
Gross Hall 2nd Floor Lighting Demand
0.3W/1000 x 8760 x$0.105kWh= $0.2759 /SqFt
Lighting
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Comparing Two Similar Floors
Hewitt Hall – 2nd floor Gross Hall – 2nd floor
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Lab Air Supply and ExhaustHewitt Hall – 2nd floor• 8 Air changes per hour minimum• No set back during unoccupied periods• Zone presence sensors on fume hoods
Gross Hall – 2nd floor• 4 Air changes per hour minimum occupied• 2 Air Changes per hour minimum unoccupied• Zone presence sensors on fume hoods• Centralized Demand Controlled Ventilation
system adjusting ACH for indoor air quality.
Lab 2501 Lab 2200
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Evidence of Where Building’sHVAC Energy Savings are Achieved
• Air change rates are dynamic responding to occupancy, IAQ, sash position, and thermal demands
• Lab 2200 averages 4 air changes per hour
• Air change rates are dependent on sash position and thermal demand.
• Lab 2501 averages 8 air changes per hour Hewitt Hall
Lab 2501
Gross HallLab 2200
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Lab Air Flow vs. Time• The HVAC savings of 1 CFM/Ft2 at $4‐5 per CFM can reduce
operational significantly.
• A 1 CFM/Ft2 reduction at Hewitt Hall in just the open lab bays would reduce operational cost by $83,250 per year
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Combining all the data:ACH vs. ΔT Operating Regions
ACH
ΔT
14
12
10
8
6
4
2
Sash and IAQ Driven ACH Governed by Plug
and Lighting Load
Optimal Region
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
High Sash and Electrical Loads or SAT too High
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Combining all the data:ACH vs. ΔT Operating Regions
ACH
ΔT
14
12
10
8
6
4
2
Sash and IAQ Driven ACH Governed by Plug
and Lighting Load
High Sash and Electrical Loadsor SAT too High
Optimal Region
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
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Solutions to ACH vs. ΔT Excursions Sash Management
Poor IAQ / Lab Practices
Over engineering Add spot cooling
Distribute lab load
Provide dedicated exhaust
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Today’s Agenda
• Welcome and Introductions• Introduction to Smart Labs• Prerequisites for Smart Labs• Lighting• Mechanical System• Determining the Potential for Air Change Reductions• Centralized Demand Controlled Ventilation• ANSI Z9.5 2012• Exhaust Stack Discharge Volume Reduction• Dashboard and Energy Savings• Constant Commissioning and Return on Investment• Conclusion and Wrap-Up• Questions and Answers
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Continuous Commissioning
-- Meaningful analysis and reports-- Actionable information-- Verification of actions taken:
physical and behavioral
CDCV Find failed lab air control
valves
Review of fume hood sash management
Ensure safe lab air quality
Find excessive air flows due to point sources of heat
Submetering Monitoring of fans, pumps,
and lighting control systems
Verification of energy retrofits
Reduce demand charges by modifying operations
BMS
Locate simultaneous heating and cooling
Reset of static pressure to minimum required
Control run times of office areas
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Troubleshooting a CO2 leakWith the CDCV System
• Researcher connects 4 tanks of CO2 to the lab distribution system and within 8 hours they are empty.
• To find the leak the research staff could have spent hours soaping lines and connections and wasting additional gas listening for the leak.
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Suspected location of CO2 leak
Researcher first plotted all rooms for CO2
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The leak was quickly located and repaired!
Researcher Then Plotted the Roomwith the Suspected CO2 Leak
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The Knowledge Center has been used to locate lab equipment placedtoo close or under thermostats.
Discovery of Lab Equipment Driving Thermal Demand
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Return on Investment
Commissioning– Cx, Rx, MBCx is approximately $2 per SqFt– Hewitt Hall MBCx $131,309– Net present value for 10 years (MBCx every 5 years) Hewitt Hall
$113,590
$(100,000.00)
$(50,000.00)
$‐
$50,000.00
$100,000.00
$150,000.00
$200,000.00
$250,000.00
1 2 3 4 5 6 7 8 9 10 11
Cumulative Cash Flow MBCx Project
MBCx Cumulative Cash Flow MBCx Net Savings
MBCx
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$(200,000.00)
$‐
$200,000.00
$400,000.00
$600,000.00
$800,000.00
$1,000,000.00
$1,200,000.00
$1,400,000.00
1 2 3 4 5 6 7 8 9 10 11
Cumulative Cash Flow
Smart CCx Cumulative Cash Flow Smart CCx Net Savings
Submetering and monitoring your lab can be very competitive with the cost of a single commissioning effort.
CDCV ~$3.12 per SqFt
Sub metering $0.20 per SqFt
Hewitt Hall Sub Metering and CDCV $302,888
Net present value for Hewitt Hall continuous commissioning (10 years) $665,903
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Return on InvestmentSmart CCx although a larger initial investment provides for greater long‐term savings as well as strategic analysis, monitoring, and savings that cannot be accomplished with traditional MBCx.
$(200,000.00)
$‐
$200,000.00
$400,000.00
$600,000.00
$800,000.00
$1,000,000.00
$1,200,000.00
$1,400,000.00
1 2 3 4 5 6 7 8 9 10 11
Cumulative Cash Flow MBCx vs. SMART CCx
Smart CCx Cumulative Cash Flow Smart CCx Net Savings MBCx Cumulative Cash Flow MBCx Net Savings
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Results:
Laboratory Building BEFORE Smart Lab Retrofit
Name Type1
EstimatedAverageACH
VAVorCV
More efficient
than code?
Croul Hall P 6.6 VAV ~ 20%
McGaugh Hall B 9.4 CV No
Reines Hall P 11.3 CV No
Natural Sciences 2 P,B 9.1 VAV ~20%
Biological Sciences 3 B 9.0 VAV ~30%
Calit2 E 6.0 VAV ~20%
GillespieNeurosciences
M 6.8 CV ~20%
Sprague Hall M 7.2 VAV ~20%
Hewitt Hall M 8.7 VAV ~20%
Engineering Hall E 8.0 VAV ~30%
Averages 8.2 VAV ~20%
AFTER Smart Lab Retrofit
kWhSavings
ThermSavings
Total Savings
40% 40% 40%
57% 66% 59%
67% 77% 69%
48% 62% 50%
45% 81% 53%
46% 78% 58%
58% 81% 70%
71% 83% 75%
58% 77% 62%
59% 78% 69%
57% 72% 61%
Type: P = Physical Sciences, B = Biological Sciences, E = Engineering, M = Medical Sciences
Page 184
• Motor and bearing wear decreased
• N+1 and greater opportunities
• Failed component detection
• Lab oversight – Hood management
– Chemical excursions
Results:
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Today’s Agenda
• Welcome and Introductions• Introduction to Smart Labs• Prerequisites for Smart Labs• Lighting• Mechanical System• Determining the Potential for Air Change Reductions• Centralized Demand Controlled Ventilation• ANSI Z9.5 2012• Exhaust Stack Discharge Volume Reduction• Dashboard and Energy Savings• Constant Commissioning and Return on Investment• Conclusion and Wrap-Up• Questions and Answers
Page 186
Future of Smart Labs at UC Irvine
Research and development of Smart Labs is an ongoing process that will continue to make our labs more energy efficient and safer.
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Lowering System Pressure DropDuct noise attenuators at lower velocity are no longer necessary and when applicable should be removed.
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LED Lighting System• LED lights with integrated smart controls• Precisely control lighting levels• Occupancy, daylighting, and temperature sensors at
each fixture• Real-time energy management and reporting• Real-time monitoring of each fixture and group• Demand response capable
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LED lighting fixtures• Pendant Mount
• 2x2 or 2x4• Can
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LED Lighting System
• Real-time and historic monitoring
• Trend energy use
• Failure notification
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Lab Display UnitsUCI working with the California Institute for Telecommunications and Information Technology is developing a new LDU that displays:
– Ventilation data
– Environmental health and safety hazard and emergency information
– Energy saving tutorials
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Lab Display Units
Touchscreen
Android-based display
Graphical output of any Bacnet point
Capable of showing • Training videos• Chemical
inventories• Scheduling• Contact
information
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The savings are building blocks and each must be completed to realize the full savings potential!
1. Complete the prerequisites
2. Safe air change rate optimization
3. Efficient lighting
4. Exhaust fan discharge velocity optimization
5. Removal of pressure drops throughout the system
6. Fume hood standby ventilation optimization
7. Final and continuous commissioning
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Today’s Agenda
• Welcome and Introductions• Introduction to Smart Labs• Prerequisites for Smart Labs• Lighting• Mechanical System• Determining the Potential for Air Change Reductions• Centralized Demand Controlled Ventilation• ANSI Z9.5 2012• Exhaust Stack Discharge Volume Reduction• Dashboard and Energy Savings• Constant Commissioning and Return on Investment• Conclusion and Wrap-Up• Questions and Answers
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QUESTIONS?Wendell Brase Matt Gudorf Marc Gomez David Kang Fred Bockmiller
[email protected] [email protected] [email protected] [email protected] [email protected]
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