Tech 3 - Harry Demetrulias Technical Session from the 2006 ASHRAE Region VI CRC

1. Temperature Controls
“Why Don’t They Work?
Harry Demetrulias

2. Top 5 Reasons
Control
Systems
Don’t Work
1. Many Controls Contractors ARE Crooks!
2. Mechanical Design Problems
3. Mechanical Installation Problems and
Equipment Malfunction
4. Operator Errors and Overrides
5. Controls Installations: Misapplied Field
Devices, Sensor Locations, Lack of
Calibration, and PID Loop Tuning

3. Blame the Owners
“Owners are too demanding and
unrealistic in their cost expectations”
Lower!
How
Low?

4. Blame The
Architects
“Architects are too
focused on aesthetics,
and do not allow
adequate space for
building systems:
Mechanical Rooms and
Interstitial Space”

5. Blame the Generals
General Contractors punch out projects
without scheduling adequate time for
Start-up, Checkout, Test & Balance, and
Commissioning activities

6. Blame the
Engineers
“Mechanical
Engineers
Overworked
and
Underpaid!”

7. Blame the Suppliers
“Equipment Suppliers
Just
SELL STUFF
and Don’t Support it!”

8. Blame the Balancer
“Do you really trust
those Test & Balance
Reports?”

9. “Should we blame those
Design/Build Mechanical
Contractors?

11. Finger-pointing
is easy
Working toward
Solutions Requires Professional
COLLABORATION

12. Function or
Malfunction is
without exception
a collaborative
effort between
Consultant,
Mechanical
Contractor,
Controls
Contractor and
Facility
Operations.

13. Temperature Control is simple.
Building Automation is complex…
How can we promote
Collaboration?

14. Delivering Truly Integrated Building Systems To Owners
Requires Collaboration
- Engineers - Controls Contractors - Mechanical Contractors
- Equipment Suppliers - Facility Operations

15. When Temperature Control
Becomes Complicated
• Economizer Mode
• Variable Volume/Flow
• Dynamic Resets
• Warm-up/Cool-down Modes
• Building Pressurization Control
• Smoke Control
•Underfloor Systems
• IAQ
• Load Shedding Programs
•TOD Scheduling
• PRAC Self-Tuning
• Integrations to 3rd Parties
• Validated Systems

16. Controls Contractor’s
Perspective:
The Consultant as
PROBLEM…or
Solution

17. Market Pressure
& the Design Community
• Hyper-competition
• Below Market Design Fees
• Allotted Billable hours for
quality designs and
specifications
• Lack of onsite Project
Engineering
• Reliance on draftsmen to
incorporate last minute
changes
• Addenda Ad Infinitum

18. The Key:
Publish Quality
Documents
Installation is only as
good as the design
Errors on P&S result
in problems in the
field
Malfunction begins in
the mind of the
designer
Unedited Master
Specifications Lower engineering
cost but…
Many Change
Orders/retrofit
corrections

19. Example #1: Nonspecific Specifications
• “DDC controllers shall be BACnet. Lonmark AND N2
Open Protocol compliant…”
• “Acceptable manufacturers are Alerton, Andover, Delta,
Honeywell, Invensys, Johnson Controls, Siemens,
Staefa Controls, Trane, or approved equal.”

20. 2. Electric, Electronic, and DDC Systems:
a. Alerton Technologies, Inc.
Example #2: b. Andover Controls Corp.
c. Automated Logic Corporation.
Healthcare project… d. Auto-Matrix, Inc.; Auto-Flow Division.
e. CSI Control Systems International, Inc.
f. Danfoss Automatic Controls.
g. Delta Controls Inc.
h. EDA Controls Corp.
i. Electronic Systems USA, Inc.
j. G C Controls, Inc.
k. Honeywell, Inc.; Home & Building Control.
I. Impact Energy Controls Corp
m. Johnson Controls, Inc.; Controls Group.
n. KMC Controls/Kreuter Manufacturing Company.
o. Landis & Staefa, Inc.
p. Luwa Bahnson Inc.
q. McQuay Intemational.
r. Neles-Jamesbury.
LOWEST TOTAL COST OF OWNERSHIP
s. Pneuline Controls Co.; National Energy Controls Corp.
t. Scientific-Atlanta, Inc.; Control Systems Div.
u. Siebe Environmental Controls; Barber-Coleman/Robertshaw
Anyone Products
v. Solidyne Corp.
w. TCS/BASYS Controls
Missing? x. Teletrol Systems Inc.
y. Trane Co. (The); North American Commercial Group.
z. Triangle MicroSystems, Inc.
aa. Uni-Line North America; Robertshaw Division.
3. Systems must interface seamlessly with existing front end control
system

21. Damper Control: When the unit is commanded on, the
Example #3: outside air damper shall fully open. When the unit is
commanded off, the outside air damper shall close. The
exhaust damper shall remain closed and the mixed air
damper shall remain open. 8 RF1ISO-S RA-F1
NC
RA-SD RA-T
(Div. 16) RA-H
VSD
NC
EA RA
10 RF2ISO-S RA-F2
HSP1-A
Set @4" NC
H L
VSD
SF-F1 SF1ISO-S 7 HUM-O
NO 0-7.5"
10-27
PFILT-A NC
FFILT-A
SA-P
Set @ 1" Set @ 1"
H L H L H L
LT-ALM VSD
MA-T HSP2-A SA-SD
3 DPR-O (38 Deg F) HUM-HL SA-T
Set @4" (Div. 16)
C
OA NC C
H L SA
4
SF-F2 SF2ISO-S 9
4 CLG-O
HUM-VLV
RETURN NC
NO
STM
NC
SUPPLY VSD
Discharge Air Temperature Control: When the unit is
commanded on, the outside air damper, return air damper, and
relief air damper will be open. Discharge temperature sensor SA-
T through the DDC Controller will modulate the cooling coil 2-way
control valve CLG-O to maintain setting. The discharge air
temperature will be controlled to maintain a 55°F setpoint.

22. Specify SPECIFICS…
Specify limited qualified
bidders that are suitable for
• market type
LOWEST TOTAL COST OF OWNERSHIP
• product application
• contractor expertise
Balance First Cost with Operating Cost

23. BAS Cross-
FIRE
VIDEO-
ON-
Referencing
DEMAND
HOTEL
ELEVATOR OPERATING
SYSTEM
IT NETWORK
LIGHTING PABX Write Specifications
that refer to other
sections and
technologies.
CENTRAL
PLANT PAGING
Detail the
responsibilities
CCTV Furnished by…
SECURITY
CMMS
Installed by…
15
BUILDING
Wired by…
SERVICES

24. Sequence of Operation
EXHAUST SYSTEM: EF-1 and EF-2
EF- EF-
Isolation Exhaust Fans EF-1 and EF-2:
EF- EF-
On command from the BAS, the fans shall start. If
Include at Minimum:
for any reason the fan status does not match its
commanded value, an alarm will be generated.
ISOLATION ROOM MONITORS Flow Diagrams
System Description:
The Isolation Rooms shall be monitored by a Space
Pressure Monitor as described in controls
specification at minimum and shall generate an Point Charts
alarm at the BAS upon general alarm or deviation
from space pressurization setpoint (adj).
adj).
Sequences

25. P.E.
Professional
Enforcer
Enforce your
specifications
Guard against cheating
in hyper-competitive
market
Get involved in
checkout, functional
testing and
commissioning
Specify Commissioning
Expectations
Review Checkout
Sheets
Verify that field
devices match the
specification

26. Resist De-Value Engineering
10. Delete lab VAV: Constant volume labs
9. Delete DDC from FCUs
8. Delete SAT Sensors on VAV w/RH
7. Delete DPs across filter racks
6. Delete interfaces to Chillers, Boilers and VFDs
5. Delete AFMS from AHUs SA/RA/OA
4. Delete VAV zones and combine multiple zones
3. Delete Custom Controls on RTUs in lieu of
packaged
2. Delete RH Coils in lieu of Cooling Only VAV
1. Delete DDC from VAV/CAV terminals

27. Technology
Capabilities of
Technology
Cost of
Technology Technology is more
affordable than ever.
But it has made
building controls more
complicated for
1990 2006 Specifying Engineers

28. Get Help from Your
Local Controls Experts
and Sales Engineers
The System Selection Tool was
designed to help specifying engineers
quickly develop detailed, accurate
plans and specifications for heating,
ventilation and air conditioning (HVAC)

29. Summary: A New
Level of
Engineering Value
$ Step 1 Publish Quality Documents
Step 2 Resist De-Value Engineering
Step 3 List Qualified Bidders
Step 4 Enforce Specifications
Step 5 Get Support and Consultation
from Reputable Controls Companies

30. Less quality in More value out
Design/Build and Value Engineering
Exploiting Owner’s Lowest First Cost Demands?

31. “We can do it
cheaper and
faster!”
Less quality in More value out
Hyper/Competitive Market and the D/B Model:
Contractors Control Design
- Reliance on Equipment Suppliers for TC
- Packaged systems w/canned programs

32. Slam it in Commission it later
Hard Bid/Design/Build
Can this building be fixed?

33. Problem: Mechanical Design & Controls Issues
– Building Pressurization Problems
– Toggling RTU Modes
– Uneven Underfloor Distribution
– Overly cool interior zones
– Overly warm exterior zones
Symptoms
– No humidity control
Building # 1
– Energy Hog—could not qualify for Energy
D/B Debacle Star rating
ASHRAE Temperature Controls: “Why Don’t They Work?”
Don’ Work?”

34. Problem: Mechanical Design & Controls Issues
– VAV w/General Exhaust System
– No trunks to distribute UFS
Causes – Improperly placed pressure sensing devices
– No calibrated primary T/H devices
Building # 1
– Cooling mode problems
D/B Debacle
– Dueling PID Loop Control on RTU
– Inability to alter or augment canned RTU
program—limitations
ASHRAE Temperature Controls: “Why Don’t They Work?”
Don’ Work?”

35. Problem: Mechanical Design & Controls Issues
– Hire a COMMISSIONING AGENT!
– Add return fans
– Add trunks to distribute UFS
Solutions – Relocate pressure sensing devices
Building # 1 – Calibrate primary T/H devices
D/B Debacle – Replace misapplied DDC hardware
– Reprogram and recommission
– Work with commissioning agent
ASHRAE Temperature Controls: “Why Don’t They Work?”
Don’ Work?”

36. Manual Control
Automation does not
work well in the “HAND”
position

37. “It’s always a
Controls
Problem!”
…often times it is…
The Controls Contractor as Part of the
Solution…

38. Controls Industry
Boilers
as the Problem:
Pumping & VFDs
Chiller
Absorption
Power
Generators
Today’s Technology is less expensive
Fan Systems But the Labor is not
Margin Expectations Continue to Rise
Fire Alarm Competition is driving the quality out
Surgical Suites
Lighting
Fume Hood

39. Today’s Technicians often
know computers but lack
understanding of basic
mechanical systems
Application Engineering &
Commissioning Challenges
Decreased skill sets in
controls software
engineering
Protocols do NOT control
buildings
Software illiteracy
Reliance on automated
Person at Metasys
processes
workstation
Lack of Quality
Management processes
What is Commissioning?

40. COMPLEXITY
Building Technology Has
Complicated Simple Temperature
Controls
Comfort
Lighting
Security
Scheduling
Access control
Fire safety
Communications
Fuel conservation
Power load
management
Maintenance
management

41. Controls Industry
as the Problem:
Value Added
Services?
Phase 1 Low First cost
Phase 2 Prices just went up!
Phase 3 Delivering less value
over time

42. Solution 1:
Can we consider
a new
Level of Value?
Phase 1 Low First cost
Phase 2 Open Book Pricing
Phase 3 Pricing Agreements
Phase 4 Meet the Specifications
Phase 5 Exceed Customer Expectations

43. Solution 2: Expert
Services
Provide support and
educational services to the
engineering community
Offer design review services
and provide input on
sequences, points lists and
specifications
Review Bid Documents and
write good clear RFIs early in
the process

44. Solution 3:
Customer & Design Team
Deliver as
Promised
General Behave more like
consulting
experts, less like
the proverbial
Crooks
Be professional and
deliver on
Performance
Mechanical Electrical Windows
Raised Floor Specifications
Contractor Contractor etc
Submit proper
Controls HVAC Lighting Fire checkout and
commissioning
documentation to
Power Consultants
Security
Mgmt
Make Buildings Work

45. Quality Assurance…
Apply ASHRAE Standards
Due diligence on
installations and checkout
practices
Tune loops and set up
trends during checkout and
commissioning
Work with Designers as
fellow engineers, not
combative contractors
Review Checkout
Sheets
Verify that field devices
match the specification

46. Working Together
we can deliver
better design and
construction
projects and the
High Performance
Buildings that
Owners are
paying for.

47. Temperature Controls
“Why Don’t They Work?
Q&A