Appendix_B_-_Requirements_Document_for_an_Energy_Management_Control_System_Rev1.pdf

Appendix B Requirements Document for an Energy Management Control

System

1.0 GENERAL

This Requirements Document (RD) provides the direction and guidance for the procurement, design, installation and implementation of the EMCS for specific facilities at Yokota AB. This system would be anticipated to be extended over time to cover every facility on the base. The process used in producing the RD will be described throughout along with factors used in the decision-making that resulted in the final recommendation. This process in general involved:

1.1. Identifying any specific or “special or unusual” requirements that the EMCS system hardware and software should possess, such as:

Expandability Dual Japanese and English language capability Open protocol language, such as BACnet

1.2. Identifying appropriate facilities to be connected to the initial EMCS taking the following factors into consideration

Ease of connecting existing facility HVAC control systems to a new EMCS Greatest return on investment in balancing potential energy savings versus installed cost Significance of facilities in supporting the general concept of reducing facility operating costs

In addition to the evaluation of the above items which are described in further detail throughout this RD, the guidance from the base staff is that they anticipate implementation of any EMCS project would be through a design-build contracting mechanism. Therefore, in addition to the development of this RD, a design-build performance specification has been included to assist in the implementation of that contracting approach. It should be noted that some information within this RD is relevant only to base personnel and as a history of things considered while developing this RD. Therefore, care should be taken to make sure only the relevant portions are released as part of a design-build RFP package.

2.0 RECOMMENDATION FOR AN ENERGY MANAGEMENT CONTROL SYSTEM

This section will provide specific recommendations and requirements for the design/build contract, as well as minimum expected functionality and components. This is intended to assist the base, as well as, the design / installing contractor for the application of the EMCS.

The following items shall be required as a minimum from the engineer of record for the design of the

EMCS:

Control system design drawings shall include schematics with point types, normal position of output devices, device ranges, initial design intent set points, and legend of device symbols. The location of flow meters shall be illustrated on the piping and or duct drawings. Remote static pressure sensors for capacity control of air and water systems shall be on the design drawings. The point list shall clearly identify all physical I/O with relations to the system and controller. The points at the minimum are DI, DO, AI, BI, AO, BO, etc. Point quantity with summary of point type, controller and system will be illustrated. Contractor shall indicate control elements on the applicable discipline design floor plans (this refers to panel locations, operator interface locations, thermostats, and temperature and humidity sensors whether in the room or in the return/exhaust duct, room differential pressure monitors, duct static pressure sensors, motor operated dampers, automated valves, etc.). This project primarily involves the installation of new DDC controls or the renovation of existing control systems. The mechanical discipline and electrical disciplines are generally required only in support of the installation of the new controls. As a result, it may simplify the drawing package if only one or possibly two sheet numbering conventions are used for the mechanical, electrical, and control disciplines. In this case, the prime contractor would likely be a control contractor that may subcontract any electrical and mechanical work required. It may be very beneficial to see the location of electrical and mechanical equipment in relation to the controls on one set of floor plans. This can simplify the use of drawings for cost estimating, installation and creating as-built drawings when completed.

Naming convention such as ME or MEC can be used to show locations for electrical panels, control panels and mechanical equipment to be controlled can be located on one set of floor plans. It is not necessary to show on the floor plans specific components that are within a unit as long as a schematic is shown for that unit and that unit is shown on the floor plan. Control drawings include schematic of the equipment to be controlled and shall indicate the systems/zones and all control system input and out-puts on a points list with summary counts along with detailed written sequences of operations for each system as discussed below. BAS and EMCS infrastructure schematics and equipment schedules must also be included on control drawings. Provide a schematic showing the project's entire BACnet communication network, including LAN devices such as routers and bridges, gateways, controllers, workstations, and field interface devices. Show connection to existing networks (as applicable).

Fully automated direct digital control systems for multiple facility designs are required.

Standardization of the BAS installation shall be across the installation to increase reliability. Written specifications detailing the Building Automation System are required for building level controls as well as network devices and software used by those devices and at the server level. All licensing of hardware and software used will be controlled by the Yokota AB was all buildings have been accepted.

Provide detailed written sequences of operation for each system. The contractor shall provide topography of equipment and a description of each action. Sequences of all HVAC modes to include on/off, occupied, unoccupied, warm-up, cool down, summer, winter, economizer shall be provided.

Include alarming with procedures on restarting the system (default mode, etc). Loss of status associated with power outages are not indicated as failures with a subsequent alarm. Provide specific directions in manuals and on the front end monitor showing directions on failure scenarios for loss of proof and all safety device trips. Show on the graphical user interface, all set points along with the actual operating points, trip points, and ranges all shall be able to be modified with the proper authorization level. This design shall show all control and supervisory VLAN’s, graphic user interfaces, alarm enunciators and printers, routers, gateways, controllers (terminal controllers can be grouped), etc. Each VLAN shall be indicated with intended media and protocols as documented in Information Assurance and PIT determination documentation. All connections to the system must be identified in coordination with the Project Officer and IA officer to ensure current requirements are met. Clarify all responsibilities for identifying IP addresses and other information when connecting to the VLAN. Routing of alarms and notifications all report on the front end and be saved to a historical file and be able to be reported in a PDF format. Alarms must be able to be prioritized in at least three levels of importance and at least three phone numbers, e-mails or texts must be identified to report the alarms. Contractor is required to validate all components and points that will be connected to the LAN and will ordinate with the base Information Assurance Group to verify connectivity and the contractor responsibilities in bringing the server online for the EMCS.

Access requirements for the BAS shall give the Project Officer and administrator assignment rights of individuals. All areas, systems, information, etc. shall meet Information Insurance guidelines in ETL 11-1. Individual users shall be given one account name and password and regardless of where they connect they will be granted access to only those functions they are authorized to use. A building system telecommunication hub and required building support hardware system for significant fiber and intranet/internet connectivity support for equipment alarm and building control system. Requirements for IP addresses shall be established and secured through Project Officer. Design shall establish the equipment numbering conventions, graphic formats and layouts, location of operator interfaces and required number of portable operator workstations. The administrator should work with the contractor for Training requirements.

3.0 SYSTEM FUNCTIONS

System functions and operation shall be defined specifically per system at the building level and the higher level EMCS platform. The EMCS shall operate on a server, furnished and installed at an owner-approved location, and integrated to each building automation system controller by means of wired network infrastructure. The EMCS function is to provide a platform for remote visual monitoring and high level control of system operating parameters (temperatures, flow rates, pressures, status) for each energy consuming system (HVAC system, lighting system, etc) in each building. The visual interface is generally through a monitor or set of monitors that can access the EMCS with a standard browsing program and the appropriate passwords. Although monitors are connected at the server, the UMCS can be accessed by users from any computer that can operate on the LAN without the use of special software with most browsers as long as the users have the proper credentials and password for access to the system. The control and monitoring functions are provided through the central server by software and associated programming. This central server and associated programming is often referred to as the “front end”. This software is recommended to contain both numeric and graphical capability, for display of systems, building floor plans, alarms, etc.

Figure 1: Example of Graphical Interface – Floor Plan

These graphics require direct programming at the EMCS front-end server level in order for the base to view and monitor these systems using the graphical display. At a minimum, a floor plan indicating zone temperatures / relative humidity / etc is required, along with a system level graphic indicating unit operational parameters (fan “on/off” status, temperature measurements, valve position, VFD %, temperature setpoints, damper positions, water flow-rates) as applicable to each system type. HVAC system types vary from building to building. These parameter values are monitored and controlled by the building level automation system and shall be communicated from this control system to the EMCS server. A network area controller is generally required for translation between the building level automation system and the EMCS operating system. There are limitations intrinsic to each manufacturer (regarding ability to integrate with other manufacturer’s systems and protocols), and therefore it is recommended to choose an open and widely used protocol for the basis of design of the EMCS operating system (i.e. BACnet). Each building HVAC system and control type will require investigation by the design engineer of record in order to properly communicate all values and parameters from the building level automation system to the EMCS. It is highly recommended to report all values from the building automation system to the EMCS. At a minimum, the system is required to report the following to the EMCS for monitoring and control:

• All analog input measured temperature and relative humidity readings (zone temperatures)

• All analog value temperature and relative humidity setpoints (zone)

• All analog input measured temperature for air-side systems (discharge air, return air, etc)

• All analog input measured temperature for water-side systems (supply water, return water, etc)

Figure 2: Example of Graphical Interface – AHU System

• All “On/Off” digital input points for system status (fans / pumps / chillers / compressors, etc)

• All “On/Off” digital output points for system control

• All analog input VFD operating point values (% speed)

• All valve positions and damper positions (digital or analog as applicable)

• All alarms and safety values (digital input)

• All schedules (timing for system operation)

These control points are wired directly to a controller that resides locally at each building.

Programming for the control sequences resides at this local building controller. The EMCS network is tied directly to this local controller through a gateway or translator which allows access to the local controller functions. The programming for each system should remain at the building level, with following minimum functions required to be capable through the remote EMCS server:

• “Global” monitoring of all measured temperatures and relative humidity

• “Global” setpoint adjustment control for temperatures and relative humidity

• “Global” On/Off control of all system pumps, fans, motors, chillers, compressors

• Scheduling update control (capable of “pushing” schedules to each building level controller)

• Visual graphic of the building with measured temperatures and relative humidity for each room / zone with corresponding setpoint

• Visual graphic with analog and digital points reported

• Visual graphic of alarms (with programmed delivery through email or messaging to HVAC shop)

• Programming and trending for each analog and digital point reported

Quantifying standardized alarms like room variance ensures that the system is operating within original design parameters and specification. Example of a recommended control sequence: When a room’s conditions result in a 5 degree variance, the system can execute a change in color to the graphical display while activating an alarm to the operator.

4.0 EMCS APPLICATIONS

The control contractor will provide innovative sequences of operation that will improve the operation and energy consumption for the systems as described below and will submit the proposed sequences at the early stages of design. The EMCS will provide the base with the ability to achieve a higher level of planned maintenance activities that enables a more efficient use of staff resources, as well as more efficient use of each system connected. EMCS allow any monitored control point the capability of trending that point over a given period of time. This can be used to monitor temperatures on every section of a floor or facility, or temperatures in an air handling unit, etc. Each of these points can be trended and reported. An operator can visually inspect trend data and can use the data to find optimal equipment operation points (temperatures, pressures, flow rates, etc). For instance, a chiller may be capable of maintaining all temperature setpoints in a building by supplying 50°F supply water temperature rather than 45°F supply water temperature, which over time may improve energy performance as well as life expectancy of the chiller compressors. The operator can change these setpoints remotely or implement programming for automated temperature reset based on when a "worst case zone” zone temperature is satisfied as long as equipment served by the chilled water can maintain humidity control for zones served. This strategy saves energy based on the conduction losses from the pipe and increased chiller efficiency but the EMCS can also provide the ability to allow significant improvements in pumping energy use through the application of variable speed drives on pumps and switching three-way valves to two way valves such that major savings can be made in energy required for pumping. Using primary/secondary or variable speed primary pumping strategies with differential pressure reset, the flow of water is controlled to meet a differential pressure at a critical point of the system. The EMCS can monitor and trend several differential pressure points and reset the values to maximize the efficiency of the flow.

During winter months, a boiler is operating at a supply temperature of 190°F or 180°F, and from inspection of the trend data of valve positions, on the coldest day of the year all valves may be observed to be only 75% open. The system may only need 170°F or 160°F supply water. The boiler can be set back to this supply water temperature, rather than operate at the original design temperature.

This can help to reduce energy consumption for the system as a whole, as well as improve life expectancy of the system. This alone can allow significant savings by reducing the conduction losses in the piping system but can also protect the non condensing boilers from receiving return water below 135°F.

The example below shows integration of an EMCS with an Advanced Meter Reading (AMR) system.

The red line represents actual amps consumed by the chiller. The blue line is the outside air temperature. The green line is chilled water supply temperature and the light blue is the return temperature. Using the trend lines to analyze the system can provide regular feedback to the maintenance shop or work crews evaluating equipment failures, cycle times, short cycling, run time, temperature setpoint failures, etc.

Figure 3: EMCS Integration with an AMR

The AMR trending is a prime example of why all data should be pulled back into the Integrated Industrial Control System (IICS) and used for the bases benefit and not just to push data to watch consumption.

The data can be set up to be visually observed and trended to allow the HVAC shop to predict best operating points (temperatures, pressures, flow rates, etc), evaluate and observe data points leading up to a system failure, and directly apply system improvements through EMCS system software.

4.1 Scheduling Function

Scheduling functions provide the end-user the ability to globally shut-down and start-up systems for all unoccupied periods of the day. EMCS is most effective when a reliable and accurate schedule is accomplished for the operation of major equipment (e.g., chillers, boilers, packaged air-conditioners, heat pumps, and lights). A building which is unoccupied should maintain programmed setback temperatures required to provide minimum comfort conditioning, ventilation and lighting during these periods. This saves not only energy, but also unnecessary wear and tear on equipment leading to unplanned maintenance costs.

4.2 Chilled-Water Reset

Typically, chilled water supply temperatures are designed at a constant temperature, with design supply water temperatures between 38F and 46F. This design temperature correlates with a maximum load or full-load for worst case cooling load anticipated for a facility. Chillers, however, usually operate at part load conditions for all other days of the year. The supply temperature no longer is required to be maintained at the original design supply temperature for these days. The supply temperature can be re-set higher to match the variable real-time building-cooling loads during part load operation.

4.3 Economizer Control

Economizer control typically requires upgrade of certain dampers for outside air, return air, and relief air from manual to automatic. In systems which are not originally designed to have economizer control, ductwork sizing, louver sizing, and configurations must be analyzed and potentially redesigned to accommodate sufficient airflow for suitable economizer operation. Once applied correctly, economizer control can provide significant energy savings for facilities requiring year-round cooling. This helps save compressor power for either a split system or chilled water system.

4.4 Hot-Water Reset Function

Like supply chilled-water temperature, the supply hot-water temperature can be reset to reduce energy consumption when the boiler is operating at a part-load condition. Besides reducing the energy used to meet the load, another benefit from resetting the hot-water temperature is a reduction in the standby losses of the boiler and piping systems. Energy can be saved in steam heating systems by maintaining supply pressure at the minimum level required to satisfy the largest heating load.

4.5 Demand (kW) Limiting Function

The global nature of the EMCS provides the end-user with the capability of remote shut-down for all applied systems at any given time. The end-user has the ability to reduce demand on any given day by shutting down systems serving non-critical zones for a period of time (generally 30 minutes to 1 hour), and cycling operation of these systems to reduce cumulative peak demand for a given time period.

This can include HVAC systems, lighting systems, or any system the EMCS controls which consumes power.

4.6 Optimal Sequencing of Multiple Chillers

The EMCS can provide remote start capability at any given time during operation for each chiller. The EMCS can monitor and start each chiller in sequence with timing between each start in order to avoid spikes in electrical demand. The EMCS can monitor all aspects of a chilled water system, as well as the zone temperature setpoints. The system can be programmed to determine optimum start timing of each chiller based on recorded trends in chilled water temperature, outside air temperature, and setpoint achievement for zones. The system can also start each chiller with anticipation of increased load based on rise of outside air temperature, helping the system maintain zone temperatures within each zone.

4.7 Duty Cycling

Duty cycling is cycling of equipment ON or OFF to control the building peak energy consumption while still maintaining comfort conditions. Duty cycling is one approach to demand limiting and is a means to change or control the duty cycle (i.e., the ratio of on-period to total cycle time) of on/off controlled equipment (e.g., unitary air conditioners, heat pumps, furnaces). For HVAC systems is usually entails changing setpoints out in building or a group of buildings so that the general effect is less electrical load on a given time, therefore reducing demand charges utility. The EMCS can also turn off equipment is nonessential during periods of demand limiting.

4.8 Tracking Energy Use

Leveraging EMCS infrastructure to track energy consumption of major end-users can be less expensive than setting up standalone systems to collect the end-use consumption data. The benefits of energy end- use tracking for an IICS manager of an installation with distributed facilities include:

• Ability to benchmark historical, normalized (i.e., with respect to weather, size, sales) end-use consumption between similar buildings/facilities. Comparison with benchmarks can help identify buildings with operational inefficiencies.

• Ability to forecast energy budgets and prepare energy purchasing plans

• Ability to track energy savings from performance contracting

• Ability to detect unscheduled operations of equipment as a result of control malfunction, bad programming or to detect controls that have been manually overridden.

4.9 Benchmark Comparisons

EMCS allows every controlled section of a floor or facility to be tracked for any controlled parameter, trended and reported. Reports can be generated to include occupancy, cooling/heating days, and benchmark comparison data.

Examples of Benchmark Comparisons

1) Energy consumption data

a) Indicate whether the results are for total energy consumed or only some of the energy consumed by the building, depending on what is currently metered.

b) Annual site energy consumption in British Thermal Units (Btu) for the preceding 12 months.

2) Benchmarking results

a) Annual site energy use intensity (Btu/gross square foot/year).

b) Annual source energy consumption in Btu for the preceding 12 months.

c) Annual source energy use intensity (Btu/gross square foot/year).

5.0 AUTHORITY TO OPERATE

Information Assurance (IA) of ICSs on military installations must be identified to include ICS systems in paragraph 5.1.2 of ETL 11-1. ICS that do NOT have a direct connection to the AF-GIG are considered platform IT (PIT) systems. If a connection to the AF-GIG exists, that connection is considered a PIT interconnection (PITI). PIT point-to-point interconnections using an Air Force Installations backbone infrastructure for the purpose of connecting to remote sensors or to another PIT capability are not considered PITI as long as they are logically or physically separated/isolated from the base common user infrastructure and system (AFNIC EV 2010—08).

6.0 ICS PIT CERTIFICATION AND ACCREDITATION (C&A)

ICS PIT Certification and Accreditation (C&A) is required for any new or existing ICS. New system acquisitions must incorporate security and IA requirements into the design specifications, and systems already in operation require IA controls as prescribed in current policy and guidance. Pit systems require IA risk assessment (RA) and periodic review as directed by the PIT designated accrediting authority (DAA).

The contractor shall be required to provide a single line block diagram of each type of ICS architecture. These diagrams should show the ICS network topology (interconnections, data flow, components, and external connections). The contractor should ensure that system connectivity is diagramed in Microsoft Visio format showing how the data flows, where the data is coming in and out, connection types (wireless, RF, Cat5/Cat6, fiber, switches, etc). If firewalls are applicable locations must be identified. All software will be provided to the Information Assurance Manager for the project. System interconnectivity shall be depicted showing all PIT components to include make and model as well as IP addresses for all that are applicable.