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Advanced Tools for Enhancing Building Performance:
Fault Detection and Diagnostic Tools
Presented by:The California Commissioning Collaborative
New Buildings Institute
December 13, 2006
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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
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Introduction to Fault Detection and Diagnostic Tools
Presented by:
Kristin Heinemeier, California Commissioning Collaborative
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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!
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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 )
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FDD Classification
Katipamula and Brambley, 2005. “Methods for Fault Detection, Diagnostics, and Prognostics for Building Systems—A Review, Part I”. HVAC&R Research, January.
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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?
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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?
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For More Information
Kristin Heinemeier877.306.CACX (2229)[email protected]
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Commercialization Partners
• Automated Logic Corporation-Eikon• Alerton-VisualLogic
• Delta Controls-GCL+
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Questions
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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
©California Commissioning Collaborative
DDC VAV Boxes: The Problem
• No appropriate way to schedule maintenance• Annual inspections: largely a waste• Wait for a complaint: poor customer service
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O&M Issues
• Need work control process• Work Order driven• Computerized Maintenance Management System
(CMMS) records history of equipment and history of contractor
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A Solution: VPACC + CMMS
• Programmed tie-in between VPACC and CMMS• Work Orders automatically generated• Directs work where there are problems before occupants
complain
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Sample Work Order
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Other Diagnostics: Similar
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Suggestions
• Can program VPACC internally if skills available• Buy with BAS products once implemented• Potential as an engineering firm offering
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Questions
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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 Administration
Jonathan Soper, Enovity
©California Commissioning Collaborative
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
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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
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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
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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
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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
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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”
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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
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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
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Case Study: Phillip Burton Federal Building
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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
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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
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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
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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
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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
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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
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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
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Electricity Consumption
Year 2004 compared with Year 2005
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Gas Consumption
Year 2004 compared with Year 2005
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Monthly Tenant Requests
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For More Information
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.
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Questions
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AEC ENFORMA Automated Fault Detection System
Presented by:
Stuart Waterbury, Architectural Energy CorporationJeff Strickland, Western Building Services
©California Commissioning Collaborative
AEC ENFORMA Automated Fault Detection System
Presented by:
Stuart Waterbury, Architectural Energy CorporationJeff Strickland, Western Building Services
©California Commissioning Collaborative
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
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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”
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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”
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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
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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
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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
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Site Configuration
Multiple buildings
Multiple sites
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Equipment Definition / Mapping
Equipment definition
Map data histories to inputs
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Equipment Tuning Parameters
Tuning parameters
Performance rules
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Results Interface
Green: proper operation
Red: faulty operation requiring attention
Yellow: emerging fault condition
Drill down for detailed fault information
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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
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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
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Initial Fault Status
Bldg84LockerRm
Drill down for detailed fault information
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Detailed Fault Report
Chilled water valve and economizer are both modulating, wasting energy.
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Fault Confirmation
Economizer Damper
CHW Valve
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Repair Confirmation
Fault has been eliminated
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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%
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Fault History: Sept 05 – April 06
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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
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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
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For More Information
Stuart Waterbury, P.E.www.enformadiagnostics.com303.444.4149Architectural Energy [email protected]
ENFORMA Building Diagnostics guest sitehttp://enformapro.archenergy.com/User Name: FDDGuestPassword: FDDGuest
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Questions
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AEC ENFORMA Automated Fault Detection System
Presented by:
Stuart Waterbury, Architectural Energy Corporation
Jeff Strickland, Western Building Services
©California Commissioning Collaborative
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
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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
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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
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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
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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
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Questions
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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/
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Thank you for attending!