presented by: the california commissioning collaborative...

©California Commissioning Collaborative

Advanced Tools for Enhancing Building Performance:

Fault Detection and Diagnostic Tools

Presented by:The California Commissioning Collaborative

New Buildings Institute

December 13, 2006


Agenda

9:30 Welcome Mark CherniackKristin Heinemeier

9:40 Introduction to Fault Detection and Diagnostic Tools

Kristin Heinemeier

9:50 NIST Diagnostics for Air Handling Units and Variable-Air-Volume Boxes

Mark CherniackJeffrey ScheinMark LeviJonathan Soper

10:40 AEC ENFORMA Automated Fault Detection System

Stuart WaterburyJeff Stickland

11:15 Final Q&A and Wrap Up Kristin Heinemeier


Introduction to Fault Detection and Diagnostic Tools

Presented by:

Kristin Heinemeier, California Commissioning Collaborative


Faults Affecting Buildings

Total: ~11% of Commercial Building energy use

TIAX LLC for U.S. DOE, 2005. Energy Impact of Commercial Building Controls and Performance Diagnostics: Market Characterization, Energy Impacts of Building Faults and Energy Savings Potential

Don’t forget the

non-energy

benefits!


Stages in FDD

Friedman and Piette, 2001. Comparative Guide to Emerging Diagnostic Tools for Large Commercial HVAC Systems

(All references can be found in the library of the California Commissioning Collaborative, www.cacx.org )

http://www.cacx.org/


FDD Classification

Katipamula and Brambley, 2005. “Methods for Fault Detection, Diagnostics, and Prognostics for Building Systems—A Review, Part I”. HVAC&R Research, January.


FDD Considerations

• What problem does it detect (is this important to you?)• Who is the user? How is it used (one-time vs. ongoing)?• What data inputs are needed? • Is it automated or manual?• How are faults annunciated?• Will it generate false positives or false negatives?• What kind of, and how much configuration is needed?• Is it sold as shrink-wrapped software or part of service

offering?


Questions this Seminar Should Answer

• How can FDD be used as a part of a commissioning process?

• What kind of specific problems do these tools solve?• What are their direct/indirect benefits and costs, and how

are they best conveyed to a potential customer or decision-maker?

• What is the market for these products, and how can a provider determine if a particular building is a good candidate?

• What is the next step for commissioning providers interested in using FDD tools in their businesses?


For More Information

Kristin Heinemeier877.306.CACX (2229)[email protected]

mailto:[email protected]


NIST Diagnostics for Air Handling Units and Variable-Air-Volume Boxes

Presented by:

Mark Cherniack, New Buildings InstituteJeffrey Schein, National Institute of Standards and Technology

Mark Levi, General Services AdministrationJonathan Soper, Enovity


Problem Statement

• Most building systems do not perform as intended– No/inadequate commissioning– Insufficient preventive maintenance– Operators respond to occupant complaints or gross failures– Undetected faults cause increased energy consumption

• Typical faults– Mechanical failures: failed/drifting sensors, stuck/failed

actuators, duct blockage, leaking valves/dampers, slipping/broken belts

– Control problems: PID loop tuning, inappropriate setpoints, manual overrides, incorrect sequences/programming

– Degraded performance: heat exchanger fouling– Design faults: undersized duct/piping, mismatched components,

inappropriate zoning


Problem Statement (cont.)

• Fault Detection and Diagnostics– Mathematical technique to detect and diagnose faults in

mechanical systems

• Energy savings– 5% to 30% of HVAC energy consumption

• Improved O&M staff productivity• Other benefits

– Improved control of space temperature and IAQ– Increased service life of equipment– Reduced downtime and overtime


Approach

• Embed FDD in Building Automation System (BAS)– Code FDD algorithms using manufacturer-specific application

programming languages• BAS provides:

– Local, real-time access to data– Platform to perform FDD calculations

• Operator interface– Use BAS alarm/event handling system– Automatic work order generation


AHU FDD

• APAR = Air Handling Unit Performance Assessment Rules• Applicable to single duct AHUs• Identify mode of operation based on control signals

– Heating– Cooling with outdoor air– Mechanical cooling with 100% outdoor air– Mechanical cooling with minimum outdoor air– Unknown

• Rule set based on mass and energy balances– Subset of rules selected based on mode of operation

• No site-specific data collection or tuning


VAV Box FDD

• VPACC = VAV Box Performance Assessment Control Charts

• Applicable to pressure independent VAV boxes• Identify generic process errors

– Space temperature error– Airflow error

• CUSUM analysis– Allows normal variation– Accumulates error beyond normal variation– Alarm limit on accumulated error

• No site-specific data collection or tuning


Field Test SitesCurrent

Site LocationAHUs VAV Boxes

ALC corporate headquarters building Atlanta, GA 2 53

Alerton corporate headquarters building Redmond, WA 1 47

Philip Burton Federal Building San Francisco, CA 2 1000

NIST campus Gaithersburg, MD 1 0

Foley Federal Building Las Vegas, NV 2 2

Montgomery College Health Sciences Building Takoma Park, MD 2 101

Pennsylvania Military Museum Boalsburg, PA 2 9

Shippensburg University Shippensburg, PA 0 28

Totals: 12 1240


AHU Faults Detected To Date

Energy Consumption

Indoor Air Quality

Occupant Comfort

Equipment Life

O&M Staff Productivity

AHU outdoor air temperature sensor drift/failure XAHU mixed air temperature sensor drift/failure XSlipping AHU supply fan belt X XLeaking AHU heating coil valve XAHU compressor failure X X XAHU logic / sequencing error (simultaneous heating and cooling) XUndersized AHU cooling coil X XUndersized AHU supply fan/motor/drive X XPoor AHU supply air temperature control PID loop tuning X XAHU outdoor air damper manual override not relinquished X XAHU supply air temperature setpoint manual override not relinquished X XAHU cooling coil actuator misconfigured XAHU/chiller scheduling conflict XAHU/boiler scheduling conflict X

Fault Description

Fault Impact


VAV Box Faults Detected To Date

Energy Consumption

Indoor Air Quality

Occupant Comfort

Equipment Life

O&M Staff Productivity

VAV box airflow (DP) sensor drift/failure X X XVAV box airflow (DP) sensor tubing blocked X X XVAV box airflow (DP) sensor tubing disconnected X X XVAV box zone temperature sensor drift/failure X XVAV box damper actuator failure X X XVAV box inlet duct blocked X X XVAV box inlet duct disconnected X X XPoor VAV box airflow / temperature control PID loop tuning X XBad VAV box minimum or maximum airflow settings X XVAV box zone temperature setpoint manual override not relinquished XVAV box controller hardware failure X X XUndersized VAV box XNetwork communication failure X XUndersized ductwork XUndersized piping X

Fault Description

Fault Impact


Commercialization Partners

• Automated Logic Corporation-Eikon• Alerton-VisualLogic

• Delta Controls-GCL+



Jeffrey [email protected]



Questions



Presented by:


Mark Levi, General Services AdministrationJonathan Soper, Enovity


DDC VAV Boxes: The Problem

• No appropriate way to schedule maintenance• Annual inspections: largely a waste• Wait for a complaint: poor customer service


O&M Issues

• Need work control process• Work Order driven• Computerized Maintenance Management System

(CMMS) records history of equipment and history of contractor


A Solution: VPACC + CMMS

• Programmed tie-in between VPACC and CMMS• Work Orders automatically generated• Directs work where there are problems before occupants

complain


Sample Work Order


Other Diagnostics: Similar


Suggestions

• Can program VPACC internally if skills available• Buy with BAS products once implemented• Potential as an engineering firm offering



Mark [email protected]



Questions



Presented by:


Mark Levi, General Services Administration

Jonathan Soper, Enovity


Need for FDD Toolsets

• New buildings often not fully commissioned• Existing buildings priority is to keep occupants

happy; can result in less than optimal system performance

• Normal RCx process will correct system problems, but often only for short term

• Preventative maintenance time consuming and expensive


How Can FDD Tools Help?

• Leave in place after Cx or RCx process has been completed

• Help ensure optimized/design sequences remain in place over time

• Identify new problems and sources of energy waste• Predictive maintenance tool• Prevent long term equipment overrides• Monitor equipment performance


Good Candidates for FDD Toolsets

• Building with modern BAS• Owner that is committed to process• Building operators with interest and sufficient

training and expertise to understand anomalies


Real Time Fault Detection Diagnostics I

• Example is VAV Box Performance Assessment Control Charts (VPACC) and Air Handling Unit Performance Assessment Rules (APAR)

• VPACC written into the VAV box DDC code and generates BAS alarm

• Alarms generated in real time, but consider error over time

• VPACC detects several VAV box problems


Real Time Fault Detection Diagnostics II

• Another example is ENFORMA• Developed by Architectural Energy Corporation

(AEC)• Anomalies generated in real time, but consider error

over time• ENFORMA obtains data from energy management

system using Tridium Niagara platform. • Diagnostics performed on server at building or

remote.• Anomalies available through web page


Trend Based Fault Diagnostics I

• Example is Performance and Continuous Recommissioning Analysis Tool (PACRAT)

• First automated diagnostic tool for HVAC system performance developed by FDE

• Separates ‘Anomalies’ from real-time ‘Alarms’ – both are important but are different (chronic vs acute problems)

• Analyzes trend data from BAS or any other source using proprietary anomaly algorithms

• PACRAT is a very flexible tool and can be customized for specific systems

• PACRAT results are provided to user online at any time via web browser – can be tracked, sorted, and filtered via system-based communication “threads”


Trend Based Fault Diagnostics II

• Currently PACRAT looks for over 25 anomalies for AHUs, chillers, and hydronic pumping systems

• Provides a platform for user-defined ‘custom’ anomaly analysis • Typically about $20,000 per building to set up; additional

economy of scale for building groups; campuses• Costs coming down as more automated procedures are

developed for data capture• PACRAT also provides historical performance metrics – min,

max, avg loads on systems; efficiency plots; etc.• Optional functionality allows for M&V-type analysis – can use

data to develop fabricated and virtual “meters” to calculate savings streams or ECM efficacy


Enovity MBPCx PG&E 3rd Party Program

• Enovity recently launched Monitoring-Based, Persistence Commissioning (MBPCx) 3rd party program with PG&E

• Traditional RCx approach followed by persistence Cx• Program requires the installation of a persistence Cx

tool at every site• Major goal is to ensure persistence of energy savings


Case Study: Phillip Burton Federal Building


Case Study: Phillip Burton Federal Building

• Largest federal office building and courthouse west of Mississippi

• Constructed in 1963• 1.4 Million sq.ft, over 20 stories and two basement levels• Enovity has held full operations and maintenance

contract since January 2004


Phillip Burton Building Ongoing Cx Tools

• Performance and Re-commissioning Analysis Tool (PACRAT) developed by Facility Dynamics Engineering (FDE)

• Fault Detection and Diagnostic (FDD) tool developed by National Institute for Standards and Technology (NIST)

• Square D PowerLogic Electrical Monitoring System


Phillip Burton HVAC & Control Systems

• Central cooling plant: 3 centrifugal chillers with primary variable flow CHW distribution

• Central heating plant: 3 gas fired hot water boilers with primary variable flow HW distribution

• Eight (8) VAV dual duct air handlers• Over 1200 VAV boxes• Alerton Envision BAS


PACRAT at Phillip Burton

• GSA hired the services of FDE to install and run PACRAT• Installed on 12 systems: eight main air handlers, three

chillers and chilled water distribution system• Generates anomaly reports every 3 months for each

system• FDE discusses anomaly reports with Enovity Chief

Engineer• Anomaly reports tied into Computerized Maintenance

Management System (CMMS) work order system


VPACC at Phillip Burton Building

• VPACC running on approximately 1000 AlertonVAV boxes and 180 ALC boxes

• Programmed to pick up seven different faults• FDD tool being used as predictive maintenance tool• In process of installing FDD on small single zone air

handlers• Creates an alarm on the BAS which is automatically

turned into a CMMS work order


Square D PowerLogic

• Monitors Over 50 Electrical Loads in the Building• Energy use and power quality can be tracked• Generates alarms that are integrated with Alerton

BAS• In process of developing automated monthly energy

reports


Improvement in Building Performance

• 8% reduction in electricity consumption in Year 2005 compared with Year 2004

• 15% reduction in gas consumption in Year 2005 compared with Year 2004

• Building comfort has improved and there have been fewer tenant requests

• Third party inspections of building have been favorable


Electricity Consumption

Year 2004 compared with Year 2005


Gas Consumption

Year 2004 compared with Year 2005


Monthly Tenant Requests



Jonathan Soper, Co-PrincipalEnovity, Inc.5 Third Street, Suite 320San Francisco, CA [email protected]

Enovity is a commissioning provider and a member of the Southwest Chapter of the BCxA. The firm specializes in commissioning and r-Cx, facility operations & maintenance, and energy engineering, with a staff of professional engineers, OM&R engineers and building technology specialists. The firm is a licensed contractor and a member of the USGBC.


http://www.enovity.com/


Questions


AEC ENFORMA Automated Fault Detection System

Presented by:

Stuart Waterbury, Architectural Energy CorporationJeff Strickland, Western Building Services


The Need for Automated Fault Detection

• Building performance, even when properly commissioned, will almost always deteriorate.

• Control systems can deviate from original design intent:– Unauthorized changes to algorithms and setpoints to “fix

problems”– Improperly maintained schedules


The Need for Automated Fault Detection (cont)

• Sensors can drift out of calibration• Equipment performance can degrade

– Economizers– Dampers– Valves

• Degraded performance can exist unnoticed for years• “No occupant complaints = No problems”


Impact of Broken Systems

• Increased energy consumption– Economizers improperly working– Simultaneous heating and cooling– Unscheduled operation

• Degraded indoor comfort– Productivity– Tenant retention

• “Silent energy leaks”


What is ENFORMA® Building Diagnostics?

• A tool for automated and continuous diagnosis of building energy system operation and performance

• Continuous fault detection ensures that buildings continue to operate according to design intent

• ENFORMA Building Diagnostics fault detection can be described as a “Smart Alarm”– Exposes problems that normal setpoint or out-of-range

alarms will miss• ENFORMA Building Diagnostics provides automated

fault detection as a plug-in to Tridium’s NiagaraAX®

platform


Applications

• Current HVAC equipment capabilities– Air handling systems (non-DX)– Chillers (beta)– Cooling Towers (beta)

• Tridium provides connectivity to nearly any building control system– BACnet, Lonworks, MODBUS, etc.– Many legacy EMS


ENFORMA Approach

• ENFORMA Building Diagnostics evaluates a variety of performance rules during every system mode:– Temperature-based rules:

• Ex: OAT=MAT during 100% outside air operation– Control-based rules:

• Ex: Economizer at minimum during heating mode– Schedule-based rules:

• Ex: Compare operational status to EMS and baseline schedules• Structure is based on NIST’s Air Handling Unit

Performance Assessment Ruleset (APAR)• If rules are violated, the HVAC system is operating in a

fault condition


Site Configuration

Multiple buildings

Multiple sites


Equipment Definition / Mapping

Equipment definition

Map data histories to inputs


Equipment Tuning Parameters

Tuning parameters

Performance rules


Results Interface

Green: proper operation

Red: faulty operation requiring attention

Yellow: emerging fault condition

Drill down for detailed fault information


How can it be deployed?

• Single-site installation– ENFORMA is installed on NiagaraAX server at each site or

building

• Multiple-site installation– Campus, multi-building enterprise, ASP– ENFORMA is installed on NiagaraAX server located at central site– Required data are archived at each site and automatically

uploaded to central server


Benefits and Features

• Exposes hidden problems that cause excessive energy consumption

• Increases O&M staff productivity: – Staff can fix underlying problems rather than treat symptoms

• Daily update of system diagnostic status• Results accessible anytime, anywhere via the internet

Case Study: Denver Athletic Club

• 250,000 SF multi-function health club established in 1882• Complete HVAC and controls retrofit completed Q1 2005

by Western Building Services, Inc.• ENFORMA Building Diagnostics fault detection system

added Q3 2005 to ensure continuous savings from the retrofit


Initial Fault Status

Bldg84LockerRm

Drill down for detailed fault information


Detailed Fault Report

Chilled water valve and economizer are both modulating, wasting energy.


Fault Confirmation

Economizer Damper

CHW Valve


Repair Confirmation

Fault has been eliminated



Preliminary Energy Impact AnalysisAnalysis period: Sept-Dec 2005

Consumption Waste

Air Handling UnitCooling (BTUH)

Heating (BTUH)

Cooling Energy Waste (BTUH)

Heating Energy Waste

(BTUH)

Percent Cooling Waste

Percent Heating Waste

Billiards Room 17 0.4 3.6 0.0 21% 0%

Centennial 251.4 6.3 34.0 0.0 14% 0%

Fitness 127.3 4.9 0.0 4%

Gym 43.4 1100.9 1.4 213.3 3% 19%

Meeting Rooms 299 138.1 23.4 62.4 8% 45%

Reading Room 29.3 0 4.4 0.0 15%

Shoeshine 34.7 129.4 5.4 16.4 15% 13%

Total 802.1 1375.1 77.0 292.0 10% 21%


Fault History: Sept 05 – April 06


Benefits for Building Owner

• Preliminary analysis found nearly 17 percent energy waste

• Faults causing this energy waste were detected by the ENFORMA Building Diagnostics system– Improper heating/cooling valve and economizer modulation

(controls)– Equipment problems (old equipment)

• Eliminated hidden problems– No occupant complaints– Systems met all temperature setpoints


Benefits for Building O&M Personnel

• Automatically and continuously monitors building operation and reports problems

• Reduces man-hours spent responding to service calls• Provides customer with convincing data on HVAC

operation and performance• Supports troubleshooting of control programming



Stuart Waterbury, P.E.www.enformadiagnostics.com303.444.4149Architectural Energy [email protected]

ENFORMA Building Diagnostics guest sitehttp://enformapro.archenergy.com/User Name: FDDGuestPassword: FDDGuest

http://www.enformadiagnostics.com/

http://enformapro.archenergy.com/


Questions


AEC ENFORMA Automated Fault Detection System

Presented by:

Stuart Waterbury, Architectural Energy Corporation

Jeff Strickland, Western Building Services


Problems solved by these tools

• Quickly identifies inadequate control sequences with minimal time spent analyzing point trends, alarms and tenant comfort complaints

• Detects sensor and actuator calibration issues

• Pinpoints inadequately tuned PID algorithms


FDD as part of the commissioning process

• Using a standard Web Browser, data can be promptly analyzed to ensure recommended changes are implemented and maintained


Benefits and how are they communicated to a potential customer or decision-maker• Increased equipment performance, energy savings, and

life cycle cost reduction can be conveyed to potential customer through the education of FDD techniques and demonstrating systems in operation


How can a provider determine if a particular building is a good candidate?• Facilities with sizeable HVAC systems managed by

people interested in long term equipment and energy performance are typically interested in these systems


Next steps for commissioning providers interested in using FDD tools in your business• Team up with control contractors and system integrators

installing and supporting Open Protocol Systems • You will need their expertise to assist in the definition

and mapping of existing control system points to the FDD system



Jeff [email protected]



Questions


Q&A and Wrap-Up

Resources• Advanced Automated HVAC Fault Detection and

Diagnostics Commercialization Program (funded by PIER)– www.archenergy.com/pier-fdd/

• California Commissioning Collaborative– http://www.cacx.org/

• New Buildings Institute– http://www.newbuildings.org/

• PIER Program– http://www.energy.ca.gov/pier/

http://www.archenergy.com/pier-fdd/

http://www.cacx.org/

http://www.newbuildings.org/

http://www.energy.ca.gov/pier/


Thank you for attending!

presented by: the california commissioning collaborative...

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