Post on 03-Apr-2018
Energy & Heat Transfer in Healthcare HVAC
12/5/2013 HAAHE/TAFHM Facility Manager Basic Training 1
Shawn Wilson, PE
TME, Inc.
swilson@tmecorp.com
Agenda
• Why target HVAC Systems?
• Shifting the Paradigm
• Controls are the Key
• 4 Opportunities
– Chilled Water Pumping
– Cooling Tower Relief
– Air Handler Controls, Resets
– Air Terminal Controls, Troubleshooting
• Closing, Q&A
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Hospital HVAC
• Unique regulatory requirements for temperature and RH, airflow, and pressure relationships.
• Special applications (Surgery, Lab, Pharmacy, Sterile Processing etc…)
• Energy intensive facilities.
• Complex Systems, Complex Controls
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Hospital Operating Costs
60% 20%
10% 3% 7%
People
Supplies
Debt Service
Energy
Other
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Hospital Business Environment
• Higher Costs
• Lower Revenues
• Insufficient Margins for Reinvestment
• Mounting Backlog of Deferred Maintenance
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Hospital Energy Costs
Average $4.09/SF
Hospital Operating and Maintenance Budgeting
27%
8%
14%
51%
Materials
Service Contracts
Staffing
Energy
Typical Hospital Operating and
Maintenance Budget ($7 to $12 per SF)
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• Reduced Operating Budgets
• Staffing Levels are already too Low
27%
8%
14%
51%
Materials
Service Contracts
Staffing
Energy
Hospital Operating and Maintenance Budgeting
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• Reduced Operating Budgets
• Staffing Levels are already too Low
• Higher Material Costs 27%
8%
14%
51%
Materials
Service Contracts
Staffing
Energy
Hospital Operating and Maintenance Budgeting
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• Reduced Operating Budgets
• Staffing Levels are already too Low
• Higher Material Costs
• Higher Service Contract Costs
27%
8%
14%
51%
Materials
Service Contracts
Staffing
Energy
Hospital Operating and Maintenance Budgeting
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• Reduced Operating Budgets
• Staffing Levels are already too Low
• Higher Material Costs
• Higher Service Contract Costs
• Energy Costs must be Reduced
27%
8%
14%
51%
Materials
Service Contracts
Staffing
Energy
Hospital Operating and Maintenance Budgeting
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Energy Use In Hospitals
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Agenda
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• Why target HVAC Systems?
• Shifting the Paradigm
• Controls are the Key
• 4 Opportunities
– Chilled Water Pumping
– Cooling Tower Relief
– Air Handler Controls, Resets
– Air Terminal Controls, Troubleshooting
• Closing, Q&A
Current Paradigm
• Selecting Systems and Equipment based on First Cost
• Using the Same Design for Every Project
• Conservative Over-Sizing of Equipment
• Selecting Systems and Equipment without Considering Current and Future Utility Rates
• Control Systems Designed by Control System Manufacturers (not the Engineer)
• Commissioning included but often becomes construction phase QC and documentation exercise.
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Current Best Practices Don’t Always Yield High Performance
• LEED
• Efficient Design
• Standard Commissioning
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LEED Certification
• LEED Buildings are no more Energy Efficient than their Peers
• More than half of LEED Buildings not eligible for Energy Star Label
• 15% of LEED Buildings have an Energy Star Rating less than 30
• LEED is not Bad…
Some Buildings not Living up to Green Label
By Mirya Navarro August 30, 2009
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Standard Commissioning
• LEED Certified Facilities have been Commissioned
• Many low Performing Hospitals were Commissioned
• Standard Commissioning is not bad…
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Potential Causes of Low Performance
• Energy Efficient Features are frequently “Value Engineered” out of the Project
• Systems are too complex for O&M Staff to Operate and Maintain
• “Drive By” Commissioning does Occur
• Facility Performance is not Measured and Verified
• Commissioning Agent Design Reviews are restricted to “Commissionability” Only
• O&M Staff have traditionally focused on Regulatory Compliance, Infection Rates, Comfort, and not Energy Efficiency
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Potential Causes of Low
Performance
• Control System Programming is not Consistent with the Design Intent
• Energy Management Systems are under Utilized
• Air Terminal Air Flow Setpoints are not Programmed in Correctly
• O&M Staff Training by Contractors does not Focus on Energy Conservation
• CxA is not Responsible for Building Performance
• O&M Staff are not Vested in a Positive Outcome
• Excess Simultaneous Heating and Cooling
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Shifting the Paradigm
Albert Einstein’s Definition of Insanity:
“Doing the same thing over and over again and expecting different results.”
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ASHE’s Commissioning Guidelines and Handbook
• Meeting the Energy Efficiency Goals is not Optional
• Current Best Practices don’t always Work
• Causes of Low Performance are Known
• ASHE’s Commissioning Guidelines and Handbook focus on Meeting Facility and Project Energy Efficiency Goals
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New Paradigm
• Construction Costs and Operating Costs must be Considered Holistically
• Minimize Reheat
• Create Synergy between Systems that Remove and Generate BTUs
• Pay Attention to the Control Programming
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Setting the Energy Efficiency Goal
“If you aim at nothing, you’ll hit it every time.”
Zig Ziglar
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Benchmarking
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• EPA “Target Finder”
• Weather Adjusted
• Occupancy Adjusted
• Free Service
• Internet Based
• Simplified Input
• Percentile Ranking
Measurement and Verification
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• Measuring on routine basis is critical.
• Review regularly.
Agenda
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• Why target HVAC Systems?
• Shifting the Paradigm
• Controls are the Key
• 4 Opportunities
– Chilled Water Pumping
– Cooling Tower Relief
– Air Handler Controls, Resets
– Air Terminal Controls, Troubleshooting
• Closing, Q&A
Designing the Control System
• Consider Design Conditions and Off-Design Conditions
• Design should Include Diagram, Sequence of Operation, Point List, Valve Schedule, and Damper Schedule
• Design should be Detailed, but not Manufacturer Specific
• Control System Design, Sequence, and Programming have more Impact on Hospital Energy Efficiency than System and Equipment Selections
27 HAAHE/TAFHM Facility Manager Basic Training 12/5/2013
Developing the Sequence of Operation
• Goal is Optimum Performance
• Include Fail-Safe Provisions
• Identify Inputs, Loop Statements, Table Statements, Logical Operators, Setpoints, Local Variables, and Outputs
• Consider Using a Flow Chart to Convey Design Intent
• Must be Very Detailed to Prevent Misunderstandings
• Lack of a Detailed Sequence is the Reason why most Buildings Fail to Achieve their Energy Efficiency Goals
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Developing the Sequence of Operation
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AHU Supply Air Temperature Reset
Control Loops
Cooling Loopout /Chilled Water Control Valve is equal to the
output of the following PI loop:
Action – Direct
Input – Supply Air Temperature
Setpoint – Cooling Setpoint
Minimum Output – 0
Maximum Output – 100
Supply Air Temperature: The supply air temperature setpoint
(“cold deck temperature”) is increased and decreased from the
minimum to the maximum and vice versa according to the
following logic:
Input – Request for more cooling from Air Terminals
Output – Supply Air Temperature Setpoint. Equal
to the lower of comparison of Calculated Supply Air
Temperature Setpoint (reset based on polling
zones described in this section) and
Dehumidification Override Supply Air Temperature
Setpoint (section 9.c).
Minimum SAT Setpoint (60F)
Maximum SAT Setpoint (65F)
Sampling Rate/Rate of Change: 1F/5 mins
Agenda
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• Why target HVAC Systems?
• Shifting the Paradigm
• Controls are the Key
• 4 Opportunities
– Chilled Water Pumping
– Cooling Tower Relief
– Air Handler Controls, Resets
– Air Terminal Controls, Troubleshooting
• Closing, Q&A
Chilled Water System Issues
• Improper Chiller, Cooling Tower, and/or Pump Sequencing
• Differential Pressure Setpoint Reset Overridden
• Condenser Water Supply Temperature Reset Overridden (or not programmed).
• Low Chilled Water Temperature Difference (Low Delta T)
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CV Primary/ Variable Flow Secondary
Chilled Water System
• First developed by B&G in 1954.
• 2 Hydraulically Independent loops via Decoupler bypass pipe (“neutral bridge”).
• Primary pumps interlocked with each Chiller to provide design (constant) gpm.
• Secondary pumps are modulated to meet system DP requirement.
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CV Primary/ Variable Flow Secondary Chilled Water System
• Perfect world – Primary Loop GPM = Secondary Loop GPM.
• No flow in Decoupler pipe.
• In the real world this is seldom the case.
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CV Primary/ Variable Flow Secondary Chilled Water System
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CV Primary/ Variable Flow Secondary Chilled Water System
KEY PERFORMANCE INDICATORS
• Secondary Loop Delta T.
– Low Delta T indicates excessive pumping.
– Chillers, AHU Coils are more efficient at higher delta T.
• System Operating DP.
– High system differential pressure can mask other problems.
– Higher DP = higher pumping horsepower.
– High DP’s can adversely affect control valve/coil performance.
T500Btu/h GPM
For a given load, Flow and ΔT are inversely proportional.
As GPM increases, ΔT drops.
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CV Primary/ Variable Flow Secondary Chilled Water System
Control Sequence
• Reset DP setpoint based on actual AHU demand (chilled water valve positions).
• Stage chillers based on tonnage but watch the temperature of water in decoupler and secondary loop Delta T for fault detection.
• Add secondary loop Delta T to dashboard.
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Variable Primary Chilled Water
• Variable Flow through Chillers
• Only 1 Set of Pumps
• Pumps Sequenced to Maintain Delta P and Minimum Flow
• Bypass Valve Modulates to Maintain Minimum Flow
• Requires Electronic Flow Safeties
• Lower Capital Cost, Energy Cost, and Maintenance Cost
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Agenda
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• Why target HVAC Systems?
• Shifting the Paradigm
• Controls are the Key
• 4 Opportunities
– Chilled Water Pumping
– Cooling Tower Relief
– Air Handler Controls, Resets
– Air Terminal Controls, Troubleshooting
• Closing, Q&A
Condenser Water Relief
• Still many plants control tower water to single setpoint (80F aquastat)
• Chiller Efficiency improves with colder condenser water.
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Lots of hours of operation – even in South Texas…
It’s all about LIFT
• Condensing temperature minus the suction temperature
• Two ways to decrease Lift by adjusting DDC:
– Lower Condenser Water Temperature
– Raise Chilled Water Supply Temperature
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Condenser Water Relief Implementation for Constant Volume Pumping
• Tower fan energy versus lower chiller kW
• Reset loop setpoint based on wet bulb and run the condenser loop as cold as possible
– 2 tower cells paired with 1 Chiller
• Be aware of lower limit.
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Variable Volume Condenser Water
System
• Valves Modulate to Maintain Proper Flow
• Flow at Design with Minimum Refrigerant Lift Override
• Chillers can Operate with Very Cold Condenser Water (eliminates transition issues with hydronic free cooling)
• Any Chiller with any Tower with any Pump
• Pumps Sequenced in a Best Efficiency Manner
• Towers Sequenced in Best Efficiency Manner
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3.0 GPM per Ton Condenser Water Flow Rate
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Agenda
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• Why target HVAC Systems?
• Shifting the Paradigm
• Controls are the Key
• 4 Opportunities
– Chilled Water Pumping
– Cooling Tower Relief
– Air Handler Controls, Resets
– Air Terminal Controls, Troubleshooting
• Closing, Q&A
Air Handling Unit Issues
• Static Pressure Setpoint Reset Overridden
• Malfunctioning Control Valves
• Supply Air Temperature Setpoint Reset Overridden
• Failed Air Flow Measuring Stations
• Malfunctioning Dampers
• Weekly Schedules Overridden
• Simultaneous Heating and Cooling
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Multiple Loop Temperature Control
Loop 1
Loop 2 Loop 3
Loop 4
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Multiple Loops
2022 Loop (0, Input, Output, Setpoint, P, I, D, Min, Max, Bias)
• 4 Setpoints
• 4 Sets of Proportional and Integral Gains
• Setpoints may Inadvertently Overlap
• Tuning is very Difficult
• Outputs will Overlap due to Hunting
• Simultaneous Heating and Cooling
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Multiple Loops
Time
Mixed Air Preheat CHW Coils
Mixed Air Temperature
Mixed Air Setpoint
Output Preheat
Temperature Preheat Setpoint
Output Coil Leaving
Air Temperature
Supply Air Temperature
Supply Air
Setpoint Output
3:00 55.3 55 51 55.3 50 0 40.7 47.5 48 24
3:05 48.0 55 76 57.6 50 24 41.6 48.1 48 27
3:10 57.7 55 42 57.7 50 0 42.0 48.9 48 26
3:15 60.5 55 33 60.5 50 0 42.2 48.3 48 30
3:20 54.9 55 51 54.9 50 0 40.9 47.2 48 23
3:25 47.5 55 79 54.7 50 18 41.0 47.6 48 23
3:30 58.3 55 39 58.3 50 0 41.8 48.4 48 28
3:35 62.0 55 29 62.0 50 0 42.3 48.7 48 33
3:40 54.1 55 55 54.1 50 0 41.4 48.2 48 21
3:45 48.5 55 75 52.9 50 11 41.1 47.6 48 20
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Overlapping Setpoints
Time
Mixed Air Preheat CHW Coils
Mixed Air Temperature
Mixed Air Setpoint
Output Preheat
Temperature Preheat Setpoint
Output Coil Leaving
Air Temperature
Supply Air Temperature
Supply Air
Setpoint Output
3:00 55.3 55 51 55.3 50 0 40.7 47.5 48 24
3:05 48.0 55 76 57.6 50 24 41.6 48.1 48 27
3:10 57.7 55 42 57.7 50 0 42.0 48.9 48 26
3:15 60.5 55 33 60.5 50 0 42.2 48.3 48 30
3:20 54.9 55 51 54.9 50 0 40.9 47.2 48 23
3:25 47.5 55 79 54.7 50 18 41.0 47.6 48 23
3:30 58.3 55 39 58.3 50 0 41.8 48.4 48 28
3:35 62.0 55 29 62.0 50 0 42.3 48.7 48 33
3:40 54.1 55 55 54.1 50 0 41.4 48.2 48 21
3:45 48.5 55 75 52.9 50 11 41.1 47.6 48 20
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Simultaneous Heating and Cooling
Time
Mixed Air Preheat CHW Coils
Mixed Air Temperature
Mixed Air Setpoint
Output Preheat
Temperature Preheat Setpoint
Output Coil Leaving
Air Temperature
Supply Air Temperature
Supply Air
Setpoint Output
3:00 55.3 55 51 55.3 50 0 40.7 47.5 48 24
3:05 48.0 55 76 57.6 50 24 41.6 48.1 48 27
3:10 57.7 55 42 57.7 50 0 42.0 48.9 48 26
3:15 60.5 55 33 60.5 50 0 42.2 48.3 48 30
3:20 54.9 55 51 54.9 50 0 40.9 47.2 48 23
3:25 47.5 55 79 54.7 50 18 41.0 47.6 48 23
3:30 58.3 55 39 58.3 50 0 41.8 48.4 48 28
3:35 62.0 55 29 62.0 50 0 42.3 48.7 48 33
3:40 54.1 55 55 54.1 50 0 41.4 48.2 48 21
3:45 48.5 55 75 52.9 50 11 41.1 47.6 48 20
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What is the Problem?
Time
Mixed Air Preheat CHW Coils
Mixed Air Temperature
Mixed Air Setpoint
Output Preheat
Temperature Preheat Setpoint
Output Coil Leaving
Air Temperature
Supply Air Temperature
Supply Air
Setpoint Output
3:00 55.3 55 51 55.3 50 0 40.7 47.5 48 24
3:05 48.0 55 76 57.6 50 24 41.6 48.1 48 27
3:10 57.7 55 42 57.7 50 0 42.0 48.9 48 26
3:15 60.5 55 33 60.5 50 0 42.2 48.3 48 30
3:20 54.9 55 51 54.9 50 0 40.9 47.2 48 23
3:25 47.5 55 79 54.7 50 18 41.0 47.6 48 23
3:30 58.3 55 39 58.3 50 0 41.8 48.4 48 28
3:35 62.0 55 29 62.0 50 0 42.3 48.7 48 33
3:40 54.1 55 55 54.1 50 0 41.4 48.2 48 21
3:45 48.5 55 75 52.9 50 11 41.1 47.6 48 20
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Single Loop Temperature Control
0
20
40
60
80
100
0 20 40 60 80 100
Ta
ble
Sta
tem
en
t
Ou
tpu
t
Supply Air Temperature Control Statement Output
Preheat Valve
First Stage Economizer Cycle(Maximum OSA Damper)
Second Stage EconomizerCycle (Return Air and ReliefAir Dampers)
Secondary Chilled Water Valve
Primary Chilled Water Valve
Stage 1
Stage 4
Stage 3
Stage 2
Stage 5
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Single Loop Humidity Control
0
20
40
60
80
100
0 20 40 60 80 100
Ta
ble
Sta
tem
en
t O
utp
ut
Return Air Humidity Control Statement Output
Disable Second Stage ofEconomizer Cycle (OpensReturn and Closes ReliefDampers)
Disable First Stage ofEconomizer Cycle (ClosesMaximum OSA Damper)
Humidifier Steam Valve
Stage 3 Stage 2 Stage 1
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Adaptive Resets
• Reset Supply Air Temperature (“Cold Deck Reset”).
• Reset Duct Static Pressure Setpoint
• ASHRAE 90.1, Energy Code
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Dedicated Outside Air AHU
• Pre-treat ventilation air. Ducted to outside air damper on individual AHUs.
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Air-Side Economizer Cycles
• Air-Side Economizer Cycles often incorrectly programmed/configured and difficult to maintain.
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Economizer Damper Control Loop not Tuned
0
10
20
30
40
50
60
70
80
90
3:0
0
3:0
5
3:1
0
3:1
5
3:2
0
3:2
5
3:3
0
3:3
5
3:4
0
3:4
5
EconomizerDamper Output
Mixed Air Setpoint
Mixed AirTemperature
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Air-Side Economizer Cycles on AHU’s with Humidifiers
• ASHRAE Standard 90.1 Requires Hydronic Free Cooling if Humidification Dewpoint is > 35 deg. F (30% RH at 68 deg. F)
• Cooling Savings are more than Offset by Higher Humidification Costs
• Air-Side Economizer Cycles are Costly to Implement and Difficult to Maintain
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Operating Room Challenges
• Surgeons/staff want 60F/50% rh
• Difficult if not impossible to achieve with typical chilled water system
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Operating Room Challenges
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Operating Room Challenges
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• Desiccant Technology provides lower dewpoints.
• Dedicated OSA AHU with Type III passive dessicant wheel shown.
Operating Room Challenges
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Air change rates, pressure differentials difficult to optimize – often are not reset based on occupancy.
Unoccupied/Occupied Reset for Operating Rooms
• Occupied – 15 to 25 ACH
• Unoccupied – 5 to 8 ACH
• DP – 0.01” w.g.
Agenda
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• Why target HVAC Systems?
• Shifting the Paradigm
• Controls are the Key
• 4 Opportunities
– Chilled Water Pumping
– Cooling Tower Relief
– Air Handler Controls, Resets
– Air Terminal Controls, Troubleshooting
• Closing, Q&A
Air Terminal Issues
• Failed Averaging Velocity Sensors
• Malfunctioning Terminal Dampers
• Malfunctioning Heating Water Control Valves
• Insufficient Air Flow to Accommodate Space Sensible Cooling Load
• Incorrect Air Flow Setpoints
• Deadband too Small
• Thermostat Range not Restricted
• Weekly Schedules Overridden
• Occupancy Sensors Overridden
• Failed Points
• Simultaneous Heating and Cooling
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VAV Air Terminal with Heating
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VAV Air Terminal with Heating – Minimizing Reheat
Best Practice: Modulate HW Valve to a Discharge Setpoint and Reset the Setpoint from Minimum up to Maximum before Increasing Air Flow.
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VAV Air Terminal Troubleshooting
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• Failed Averaging Velocity Sensors
• Malfunctioning Terminal Dampers
• Malfunctioning Heating Water Control Valves
• Insufficient Air Flow to Accommodate Space Sensible Cooling Load
• Don’t apply a system wide correction to a zone level problem.
Closing Thoughts • You can’t manage what you
don’t measure.
• The code is the key. Get it right and good things happen.
• Don’t use a sledge hammer to drive a finish nail.
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Thank You! Questions?
“The only constant is change.” - Heraclitus
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©2012 American Society for Healthcare Engineering of the American Hospital Association 71
“It is not the strongest of the species that survives, nor the most intelligent that survives. It is the one that is the most adaptable to change.” Charles Darwin