Design Building Energy and Environmental Management and Control System

D ESIGN : B UILDING E NERGY AND E NVIRONMENTAL M ANAGEMENT AND C ONTROL S YSTEM
4th Year Sustainable Design Practical Final Report
Candidate: Chris Pullen Student Number: D00131950 Course Code: DK_ESUSD_8 Y4
Lecturers: Tim Daly Pdraig McGuigan Kimmitt Sayers
Student Number: D00131950
DESIGN: BUILDING ENERGY AND ENVIRONMENTAL MANAGEMENT AND CONTROL SYSTEM

4th Year Sustainable Design Practical Final Report
FOREWORD
This document and the content herein have been compiled from research and practical works carried out by Chris Pullen at Dundalk Regional Technical Institute and at various select Industrial premises within Ireland. This project has been submitted for assessment and consideration for credit against an Honours Engineering Degree in Sustainable Design. This project was extremely large in scope from the perspective of design and technical difficulty. It was not possible to completely design, test and deploy the complete system concept within a timescale of only 2 semesters due to the limited resources available. However the aim of this project was to implement some of the more novel and exciting features of the system and thereby prove the concept is valid and technically sound. A Bonus target was set to actualise the project into a saleable product and to validate the concept by proving that a real life market exists. The product name will be referred to by the acronym BEEMS for conciseness within this report (Building Energy Environmental Management System). The concepts and features developed for BEEMS were borne out of a great deal of application of thought and experience in Industry by Chris Pullen. A consultation process was
undertaken with Dundalk Institute of Technology Engineering faculty and with several potential Industrial customers.
The consultation process had three important outcomes. Firstly it confirmed through market and technical research that the product concept was not only feasible but also marketable. Secondly it highlighted and prioritised desirable features of the product. Thirdly it allowed the project Supervising Lecturers at Dundalk Institute of Technology assess and guide the project from a broader perspective, which included industry data and feedback, rather than working with just theory and a prototype. This allowed for the setting of clear project deliverable goals. There are of course similar products on the market. Building management systems (BMS) are very common indeed. However what has been achieved with this product is a smarter, more cost effective and more flexible system design than anything else currently available on the market. The product delivers real cost savings and environmental benefits. It is cost positive due to the short return on investment (ROI) period. Therefore the BEEMs system is a triumph in Sustainable Design and a validation of the ideology and thesis behind the Sustainable Design Practical course at Dundalk Institute of Technology.
STATEMENT
OF
ORIGINALITY
I hereby state that the works and concepts carried detailed in this report are the work of Chris Pullen except where other sources are credited. All site works and data collection has been undertaken by Chris Pullen and not by any other party. This is an original work and assistance from third parties is acknowledged at the end of the main report.
Signed:_____________________
Dated:______________________
Table of Contents
Foreword.......................................................................................................... 2 Statement of Originality ..................................................................................3 Table of Contents.............................................................................................4 ........................................................................................................................ 8 Goals for Semester 2........................................................................................8 BEEMS Goals Category Diagram....................................................................11 Gantt Chart.................................................................................................... 12 IPPC licence Management through BEEMS.....................................................13 Instrument Panel with IPPC configured BEEMS at BOC Gases.....................15 Discharge to Sewer Monitoring point........................................................15 Rain Gauge Installation ..............................................................................15 Trend produced illustrating discharge flow.................................................15 Trend produced illustrating site rain fall.....................................................16 Trend produced illustrating discharge flow and Rain fall............................17 The Mogden Formula...................................................................................18 Understanding the Mogden Formula...........................................................19 Calculating Rainfall footprint of BOC site....................................................21 IPPC BEEMS Business Potential.................................................................21 Business Potential of IPPC Market in Republic of Ireland.............................22 Boiler / Energy Efficiency Management through BEEMS.................................24 Boiler Under BEEMS Control........................................................................25 BEEMS Algorithm for monitoring the Boiler efficiency.................................27 The following plots are MatLab modelling results of the algorithm.............32 MatLab Code for BEEMS System Boiler Control Algorithm ........................40 Photos - Trinity College Boiler rooms at the McNamara Building................45 Photos from DkIT Boiler house - appraisal visit..........................................45 Costings for the implementation of Boiler Energy Efficiency Testing .........45
Costings for the implementation of Fugitive gas with BEEMS system.........45 BEEMS system hardware costs (additional to either of above costs)..........46 Tumble Dryer Energy Management through BEEMS......................................47 Testing Strategy..........................................................................................48 Sensor and Transducer Installation.............................................................50 Handheld Instruments and BEEMS data logging.........................................50 Data Analysis - Graphical Display (Mimics) for live test data.....................50 Data Analysis - Trending modified-v-unmodified Vent Temperature ..........51 Data Analysis - Trending modified-v-unmodified Power Consumption.......54 Data Analysis - Spreadsheet Power difference in Vented Air Masses........55 Sample Open Source Code for Dryer Testing..............................................55 Fugitive Gas Detection and Alarming using BEEMS........................................56 ....................................................................................................................... 56 About Fugitive Gas......................................................................................57 Fugitive Gas Monitoring Setup....................................................................59 Data Analysis Trending of Boiler House Gas Data...................................59 Flexible connectivity...................................................................................63 Mimics and user interface...........................................................................64 Example: Trending viewed through Internal Wed server mimic...............65 Example: Live data viewed through internal web server mimic...............65 Example: Data retrieve embedded into internal web server interface.....66 Example: Channel Text listing viewed through internal web server........66 Data trending..............................................................................................66 Alarm Logging and Reporting......................................................................68 Example: Text Report file generated from logged data..........................68 Example: Alarm report automatically generated.....................................69 Legislation and funding..................................................................................70 Acknowledgements........................................................................................70 Appendix........................................................................................................ 71 Sample Open Source Code for Dryer Testing .............................................71 DT85 Specification sheet.............................................................................73
Summary of Semester 1 Report Content

The report compiled for Semester 1 covered the following topics:
Identify and establish a need for the product. Industrial User Interviews (potential customers) o BOC Gases o Green Star , KTK facility o Trinity College Dublin
Product Definition o Product description o Problem Statement o Product Definition
Topology of BMS systems currently on the Market The BEEMS system o Overview of advantages of BEEMS over existing BMS o BEEMS with conceptual Data over Mains (SCOM) system
o o
Diagrammatic Illustration of Key BEEMS applications Narrative of Key BEEMS applications
Project Objectives o Degree Credit o Sustainable Product Design

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Monitoring Control Reporting
o Cost Savings
Integration of OTS (off the shelf) Systems Intelligent Application and Bespoke Algorithms
o Diagnostic and Analysis tools Facilities (Estates) Management Health and Safety Management Personnel Management Environmental Management INvironment and Psychrometric Management Energy Management
o Triple Bottom Line and Capital expenditure justification.

o
Proposed Project Targets for Semester 2
Boiler / Energy Efficiency Management through BEEMS IPPC licence Management through BEEMS Data over Mains (SCOM) communications with BEEMS GUI with BEEMS Mimics and user interface Data trending Alarm Log / Reporting
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2-way SMS alarming and control through BEEMS
Outline of preliminary Boiler Control and management Algorithms.
Outline of preliminary IPPC management Algorithms. Acknowledgements. Appendix of Research and support materials. Glossary of terms.
GOALS
FOR
SEMESTER 2
At the beginning of semester 2, after consultation with Tim Daly and Pdraig McGuigan, it was decided that the BEEMS project was in danger of becoming undeliverable unless tight goals were defined and focus on. The concept of the BEEMS system is extremely large in its scope and the duration of semester 2 was quite limited. In order to set these goals the following was done:
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Progress from semester 1 was reviewed. Features required to market BEEMS to industry were considered. Available time, equipment and facilities were assessed.
Progress from Semester 1 was reviewed and it was felt that the marketing and research strongly suggested that the BEEMS concept was viable as a product. The technologies involved were realistic and the costings indicated the product would be attractive to consumers. Critical analysis suggested that the project would have to be narrowed significantly in order to successfully deliver the project on time and functional.
Features required to market BEEMS to industry were considered. In order to market the system the GUI would need to allow the customer to trend historical data, to allow live viewing of parameters on screen (preferably via an mimic), a reliable connection to the customers PC must be available and alarming and reporting would be required. The BEEMS system concept incorporates a suite of Pre-configured tools for handling various building, energy and environmental management tasks. At least 1 of these pre-configurations would have to be completed and tested to deliver a product to market. Critical analysis suggested that a Beta site would be required to prove the system works as expected and to quantify a cost-benefit analysis for marketing purposes.
Available time, equipment and facilities were assessed. It was decided that the amount of work to be done in semester 2, in order to deliver a completed project, was immense. The time scales were very tight so a Gantt chart was produced and the tasks associated with each goal was entered onto it. This allowed for the time management to be quantified and some facets of the project (such as the SCOM system) proposed in semester 1 were not pursued in semester 2. The Gantt chart was a very useful tool to critically analyse the time management of this project.
The outcome of this process was the setting of the following goals: 1) IPPC licence Management through BEEMS 2) Boiler / Energy Efficiency Management through BEEMS 3) Fugitive Gas Detection and Alarming using BEEMS 4) Back End (User end) software interfacing to BEEMS a. Mimics and user interface b. Data trending c. Alarm Log / Reporting
Some Bonus goals were set but would only be pursued after goals 1 4 above were achieved or significantly progressed. 5) To implement SMS alarm and control. 6) To realise the marketing and sale of the BEEMS system to Industry.
Critical review of the project as outlined above also lead to the decision not to proceed any further with the SCOM feature. The time and resources required to deliver this feature were too great for the scope of this project. The decision to sideline the SCOM feature was important and was a result of the application of project planning and management.
The Diagram shown on the following page (10) illustrates the goals set. Each Boxed area of the BEEMS system represents a project goal. These goals were laid out chronologically and broken down into sub tasks. They were charted on a Gantt chart which is included on page 11 of this report.
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BEEMS G OALS CATEGORY DIAGRAM
11
GANTT CHART
12
IPPC
LICENCE
MANAGEMENT
THROUGH
BEEMS
13
The Diagram on the previous page (12) shows the IPPC management portion of the BEEMS system indicated in a grayed out box. An IPPC licence is an integrated Pollution Prevention Control licence. These are issues by the EPA (environmental protection Agency) to industrial site operators where there is trade effluent deemed potentially hazardous to the environment. The IPPC licence imposes strict monitoring and control criteria on the licensee. Ongoing monitoring of effluent quality and quantitive parameters is required to ensure that any exceedances above or below limits set out in the IPPC licence are recorded and reported. IPPC licence holders must bear all costs for the implementation of the IPPC licence. Apart from the Cap-ex costs of the monitoring equipment they also face significant ongoing cost for the reporting and maintenance of their system(s) to comply with their licence conditions. As part of this project a configuration was developed for the BEEMS system to minimize the human input required to implement the IPPC licence. This is by itself an attractive feature from a cost saving point of view. However an additional Algorithm was developed to quantify the volume of rain fall ingress from the customers site footprint into the fouls sewers. Rain water (or storm water) should be separated out and directed to the storm water drains where it then is discharge to rivers. When storm water ingress to foul sewers occurs the IPPC licence holder must pay the local authority for the treatment of this rainfall as if it were trade effluent. The charge for this treatment is based on the Mogden formula and is qualitive as well as quantitive based. The BEEMS system allows the IPPC holder to prove to the EPA and/or local authority that a quantified volume of the trade discharge is in fact storm water. This is used to then reduce the treatment bill form the local authority. It can also be used internally (within the IPPC licensed company) to justify cap-ex budgets and to calculate the time to recoup the costs of remedial civil works through reduced charges. The IPPC configured BEEMS system was installed in BOC Gases on the Naas road in Dublin. The configuration was localized to their particular licence and Beta tested over the course of 2-3 months. Data was then collected and analysed and reports generated for the customer to supply to the EPA for their quarterly report. The volumes of rainfall and the man hour savings were quantified. BOC were very happy with the
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results and the ROI period. They decided to purchase the system and are now considering systems for Belfast and Cork. The following pages show the Beta system in situ as well as the data analysis and the calculations required for the discharge to sewer monitoring.
Instrument Panel with IPPC configured BEEMS at BOC Gases Diagram removed;
Discharge to Sewer Monitoring point
Rain Gauge Installation Gauge Mounted on Pole. Mechanism. Self emptying Tipping
Trend produced illustrating discharge flow
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Trend produced illustrating site rain fall
16
Trend produced illustrating discharge flow and Rain fall
17
The Mogden Formula
18
Factories and soon restaurants, pubs, farms and hotels will have to adhere to strict effluent discharge conditions as set out in an IPPC licence. If this effluent (waste water) is discharged to foul sewer it will ultimately end up in a municipal sewage plant. Since the local authority has to burden the cost of treating this effluent it recoups the cost (plus a handsome profit) by levying charges per cubic meter treated. These charges are calculated based on a number of parameters based on the quantity and quality of the effluent. In order to accurately and repeatedly assess the charges to be levied on the IPPC licence holder an industry standard formula called the Mogden formula is employed.
The Mogden Formula is as follows: C = R + V + Vb + (B x Ot/Os) + (S x St/Ss) Where: C = Total charge rate for disposal (Euro/cubic metre) R = Unit cost for conveyance (Euro/cubic metre) V = Unit cost for volumetric treatment (Euro/cubic metre) Vb = Additional volume charge if there is no biological treatment B = Unit cost for biological treatment (Euro/cubic metre) Ot = COD of trade effluent (mg/l); Os = COD settled sewage (mg/l) S = Unit cost for sludge disposal (Euro/cubic metre) St = Solids value trade effluent (mg/l); Ss = Solids value* settled sewage (mg/l)
Understanding the Mogden Formula

19
Waste water treatment costs are dependent on the local authority rates as well as: 1) Volumes discharged 2) COD (Chemical Oxygen Demand) 3) Suspended Solids 4) BOD (Biological Oxygen Demand) The treatment charges can be reduced by reducing any of the parameters in the Mogden formula. The BEEMS system reduced these costs by accurately quantifying the discharge volumes, quantifying the ration of trade effluent versus storm water and on larger systems calculating the costs at the licence holders site itself by measuring the water quality parameters using inline probes. The Mogden formula also allows for the charging for treatment for storm water volumes (Vb) as well as trade effluent volumes (V). This is becoming more and more common as local Authority want industry to remediate their storm water and foul water systems. This reduces the treatment plant energy costs but saddles effluent discharge industries with the cost of the remedial civil works. However the BEEMS system will still significantly reduce the treatment costs as the tariff for Vb can be as little as 20% of the tariff for V. Therefore the more storm water that can be proven to be a component of the total discharge volume, the lower the treatment cost.
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Calculating Rainfall footprint of BOC site
Site footprint in square meters = 19,918 m3 Total Q1 rainfall in meters = 0.1253 m (from Rain gauge / BEEMS) Total rainfall Discharged Q1 2011 = 2,496 m3 ( Total Rain x Footprint ) Estimated Annual Rainfall discharge to sewer = 10,000 m3 Estimated treatment cost for Rainfall discharge = 8,700 per annum BEEMS system cost = 10,000 (once off Capital expenditure) BEEMS maintenance cost = 1,100 per annum
Estimated Return on Investment Period = 18 months.
IPPC BEEMS Business Potential ORDERS FOR SYSTEM ALREADY ACHIEVED Client BOC Gases Description Order Value
IPPC Management system Dublin Plant ~ 10,000 [ Cork and Belfast sites under consideration]
Uisce Technology IPPC Management system - Trial site #1 ~ 6,000 Uisce Technology 6,000 Uisce Technology 6,000 Uisce Technology 6,000 IPPC Management system - Trial site #1 ~ IPPC Management system - Trial site #1 ~ IPPC Management system - Trial site #1 ~
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[Up to 20 sites per year under consideration] IFM IPPC Management system Galway Trial ~ 4,000 [ 3 Other Sites under consideration] Total ~ 38,000 The figures above illustrate the IPPC configured BEEMS system sales as of 20th April 2011. The difference in the cost for the systems is accounted for as follows: The BOC order was a complete turnkey supply, install and commission. Hence the system cost is full anticipated retail cost. The Uisce Technology orders are on a supply and final commission basis and the installation costs are borne by the customer. So there are significant Labour and sundry parts savings compared to the BOC sale. Also there is some quantity discount included as the customer ordered 4 systems to assess. The IFM sale is for supply only and all install and commission is at the remit of the customer. Hence the relatively low price. The differing technical support requirements of these orders will help to highlight any technical issues with the product delivery.
Business Potential of IPPC Market in Republic of Ireland

EPA Licences granted in 2009: EPA Licences granted in 2008: EPA Licences granted in 2007: EPA Licences granted in 2006: EPA Licences granted in 2005: EPA Licences granted in 2004: EPA Licences granted in 2003: 54 40 51 34 27 31 38
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EPA Licences granted in 2002: EPA Licences granted in 2001: EPA Licences granted in 2000: EPA Licences granted in 1999:
36 44 59 73
Total Number of IPPC licences listed on EPA.ie : 1025 County/City councils: Borough councils: Town councils: 75 34 5
Estimated Number of Discharge licences : 4000 10% Market share: [conservative] 20% Market share: 500 @ 5,000 = 2.5 million 1,000 @ 7,000 = 7 million [optimistic]
Potential added value items (service & spares): = 375K - 1 million Gross Profits: 40% (Product Sales), 55% (Value added Service work). These figures are current market value not per annum values. However legislation changes will bring Restaurants, hotels, bars, farms and many other industries under the IPPC umbrella making the figure above realistic annual targets going forward.
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BOILER / ENERGY EFFICIENCY MANAGEMENT
THROUGH
BEEMS
24
The above diagram shows the Boiler / Energy Efficiency Management feature of BEEMS as indicated by the grayed box which is the second project goal.
Boiler Under BEEMS Control
Theory of operation In Figure B1 above the Thermostat (1) is a temperature sensor, normally a simple Bi-metallic strip, used for crude ON/OFF control of the Boiler Burners. With the BEEMS system temperatures from several rooms could be aggregated to determine the burner requirement. The circulation Pump (11) could be replaced with a Variable speed drive under the governance of the BEEMS system. This would allow for very close matching of output to demand. It would also reduce overshoot of the system which would reduce Energy wastage. In order to reduce costs and for ease of retrofitting existing Boiler systems the BEEMS system could employ existing circulation pumps with the addition of a proportional control valve. The BEEMS system could implement PID control techniques on the control system to give a very smooth and accurate environmental response.
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The Boiler Controls (2) would still operate the boiler but only in the crude ON/OFF fashion originally designed for. The Controls (2) only job is to switch the Burner (3) in and out as demand requires. This is done by means of an integral solenoid valve and switching power through to the Fuel Pump (4) (Note: if the fuel is gas then there is no fuel pump but rather a spring closed valve known as a slam shut valve). The Fuel Pump sucks oil through the filter (5) and delivers it under moderate pressures to the burner nozzles which protrude into the Burn Chamber (6). The nozzles need oil delivered at pressure so they can aspirate (create a mist or spray) the oil which allows for efficient mixing with the second combustant, i.e. Oxygen from air. This fuel/air mix is ignited by either a spark or a pilot flame (depends on the fuel and the system setup). During operation the combustion box gets extremely hot. At this point the combustion thermal energy heats the Heat Exchanger plates (10) (Also called the Boiler because this is where the water in the system gets heated). The Hydronic system passes water (or a thermal oil or a water glycol mix) through the heat exchanger via a series of small gauge pipes that pass back and forth through the heat exchanger block. The heated water is pumped through the delivery side of the system by means of a Circulation Pump (11). An Expansion Vessel (12) is located on the hot feed flow line from the Boiler. This is a critical piece of equipment. Since the system is a closed loop system and water cannot be compressed, then , should the water get too hot it cannot expand or compress. It would be trapped in the pipe work of fixed dimensions until the heat energy in the water would overcome the material strength of the weakest parts of the system. The result would be a blow out with super hot water (steam) being ejected. This would be very dangerous as well as costly in terms of damages. The expansion vessel is filled with slightly compressed air (0.5 to 1 bar in a domestic system would be typical). As the system heats up the water can expand by further compressing the air in the expansion vessel. Since the water cannot be compressed then the force of the air in the vessel expanding is transferred hydraulically through the water. A
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Pressure relief valve close to the boiler will blow open relieving the pressure in a controlled fashion should the system get too hot and therefore the system pressure get too high.
BEEMS Algorithm for monitoring the Boiler efficiency The concept behind the BEEMS system is to allow for intelligent management of energy and environmental parameters within the remit of its building management role. Therefore as part of this project two features were explored that offer users real cost savings and genuine improvement over current typical setups. These features are not exhaustive. They are to demonstrate the potential of the product. Time and resource limitations prevent further development of the Boiler management at this time. The first feature explored is the monitoring, in real time, of the boiler efficiency. This allows users to then: View trends (historical data) Generate energy efficiency reports The data can be used as a powerful tool to o Improve the boilers usage o Determine optimal service intervals
Generate Automatic alarms via various communications methods (especially SMS) Allow for restarts in trip situations remotely (especially by SMS) Monitor and report TWA (Time Weighted Averages) Health and safety requirements. Monitor and report STEL (Short Term Exposure Levels) Health and Safety requirements. Automatically trigger a Slam shut valve on the gas supply line in case of fugitive gas detection (gas leak)
27
The algorithm developed for the energy efficiency is as follows: Energy out of Boiler = [(Tout Tin) x Qout*] x Specific heat capacity of hydronic fluid Qout = hydronic fluid mass flow = Volumetric flow x Specific gravity of fluid.
*
Energy in to Boiler = Qin x Net Calorific value of fuel. Boiler Efficiency % = Energy out Energy in X 100%
As already stated the concept behind the BEEMS system is to allow for intelligent management of energy and environmental parameters within the remit of its building management role. So the Algorithm developed above is a very useful management tool for monitoring the boiler operation. The next step is to develop another Algorithm for the BEEM system to Control the boiler operation as efficiently and smoothly as possible. To summarise the exploring Figure B1 the BEEMS system could be used to tightly and smoothly control the output of the boiler based on temperature(s) in the INvironment. The thermostat would become only a fall back control (becomes a failure scenario rather than the norm in an ON/OFF control methodology). The addition of a Proportional control valve on the Boiler output would allow for variable flow rates and therefore variable heat delivery into the Invironment. The following is the development of an Algorithm to control this Variable heat delivery system. Figure B2 illustrates the Algorithm in a block diagram fashion. The set point is the desired temperature to be obtained from the heating system. The controller is the BEEMS system ( or more accurately the algorithm about to be developed here). The Valve is the proportional control valve that can be used to throttle the Heat flow rates. The heat Exchanger is the Boiler itself and would need to be tuned for each Boiler by plugging in manufacturers data. Alternatively the Boiler Efficiency algorithm previously developed could be used to achieve this tuning. The last element in the model is the feedback component
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which is a temperature sensor (or sensors) placed in the Invironment to be temperature controlled. The Controller will require PID (proportional Integral and Derivative) functionality, the Valve will be modelled by a first order lag plus gain, the Heat exchanger will be modelled by two first order lags plus gain (which is really one second order component broken into two first order factors i.e. one for each temperature component in the heat exchanger), The temperature feedback is also modelled by a first order lag and gain.
Now that a block diagram model for the control system has been developed it is necessary to progress to a mathematical model. This is done below in Figure B3. First the open loop response for the model is determined. This was done using a software package called MatLab. The Program used for the system model can be seen on page 31. However first a discussion of the Model illustrated in Figures B3 & B4 (page 30) is required. Under ideal circumstances the temperature out of the system (right hand side) should be equal to the set point fed into the system (on the left hand side). However disturbances in the system will lead to errors and therefore drift between the desired and the actual temperature. To overcome this the controller will act to position the valve until the heat released from the heat exchanger is such that the output temperature is equal to the set point (actual = Desired). Therefore the error will be Zero, The temperature sensor provides the signal being fed back for comparison with the set point and the control will act proportionally to the size of the error between the actual and the desired temperatures.
29
30
The following mathematical operators have been used: s=tf('s'); S is a Laplace Transfer function so we dont need to do any calculus Kp= PID proportional gain constant Kd= PID derivative gain constant Ki=PID integral gain constant Kv=Valve Gain constant Kh=Heat Exchanger gain constant Kt=Temperature transducer (feedback loop) gain constant Tv=Tau constant for Valve Th1=Tau constant 1 for Heat Exchanger 1st order Th2=Tau constant 2 for Heat Exchanger 1st order Note: (Th1xTh2) gives a 2nd order Tt=Tau constant for temperature transducer. T=Sample period A = Kp*(1+Kd*s+Ki/s) V = Kv/((Tv*s)+1 = PID response model = Valve response model
HE= Kh/(((Th1*s)+1)*((Th2*s)+1)) = Heat Exchange response model

31
TT=Kt/(Tt*s+1) model
= Temperature feedback sensor response
OLT=(V*HE*TT) = the Open loop transfer function to a step response of the system CLT=(Kp*V*HE*TT) = the Closed loop Transfer Function (PID excluded for OLT not for CLT) CLT=(Kp*V*HE)/(1+(Kp*V*HE*TT)) = Calculate Closed loop function with feedback, P only. CLT=((Kp*(1+Kd*s))*V*HE)/(1+((Kp*(1+Kd*s))*V*HE*TT)) = Add Derivate gain to PID model. CLT=((Kp*(1+Kd*s+(Ki/s)))*V*HE)/(1+((Kp*(1+Kd*s+(Ki/s)))*V*HE*TT)) = Add I gain to PID .
The following plots are MatLab modelling results of the algorithm.
32
Valve Model Transfer Response to Step input.
As expected the response is first order Lag + Gain in nature.
33
Heat Exchanger Model Transfer Response to Step input.
As expected the response is second order Lag + Gain in nature.
34
Temperature sensor Model Transfer Response to Step input.
As expected the response is 1st order Lag + Gain in nature.
35
At phase angle of -180 Deg the frequency is 0.389 radians/second. At 0.389 radians /second the Gain margin is -13.9 dB. =>13.9dB = 20 log (Gain) =13.9/20 = log (gain) =>0.695 = log (gain) Gain = 100.695 => Gain = 4.955 (max gain) (above this system unstable)
Open Loop Transfer Function Bode Plot of frequency to determine Gain Margin for Controller.
36
The Transfer response is unstable in this plot. This is because the Kp (Proportional gain) was set to 6 when we had calculated the gain margin to be 4.955. SO this response is as expected and proves our gain margin calculation. Notice the Oscillation growth. This could be destructive to equipment if implemented in the real world. Our Algorithm for the BEEM system wont do this because of our Mathematical modelling/Simulations.
Closed Loop Transfer Step Response with Gain Margin in unstable region.
37
Gain of controller (P only gain) kept below gain margin of 4.955 so the response is stable . However the overshoot is quite large at approx 25%. So we need to add some Integral gain to slow the rise ramp up rate. Overshoot has a cumulative tariff on energy costs so we want to Dampen the response to get a fast and smooth response.
Closed Loop Transfer Step Response with Gain Margin in stable region.
38
We added a small amount of Integral Gain but it made little difference for this system. This is expected because the Integration of a step is approximately the same shape as the plotted response anyway. We now need to see if adding Derivative Gain (Kd) will Help to dampen the system response. It should as this type of gain has a Predictive nature. Notice the steady state level has increased due to the extra gain of the controller.
Closed Loop Transfer Step Response with Integral (Ki) as well as Proportional (Kp) Gain.
39
This is a beautiful response. Notice how smooth the rise is and notice that we have virtually eliminated overshoot. This algorithm would give a very energy efficient control on our BEEM system boiler control. Also the steady state error is very flat so the valve will not be hunting unnecessarily.
Closed Loop Transfer Response with Proportional (Kp), Integral (Ki) and Derivative (Kd) Gain.
MatLab Code for BEEMS System Boiler Control Algorithm

40
s=tf('s'); % Setting S as a transfer function Kp=9; %PID proportional gain constant Kd=1; %PID derivative gain constant Ki=1; %PID integral gain constant Kv=1;%Valve Gain constant Kh=10;%Heat Exchanger gain constant Kt=0.1;%Temperature transducer (feedback loop) gain constant Tv=1.5; % Tau constant for Valve Th1=5; % Tau constant 1 for Heat Exchanger 1st order Th2=3;%Tau constant 2 for Heat Exchanger 1st order (Th1*Th2) gives a 2nd order Tt=2;%Tau constant for temperature transducer. T=1; %Sample period %% A=Kp*(1+Kd*s+Ki/s); figure(1) step(A); %% V=Kv/((Tv*s)+1); figure(2) step(V); %% HE=Kh/(((Th1*s)+1)*((Th2*s)+1));% figure(3) step(HE); %% TT=Kt/(Tt*s+1); figure(4) step(TT); %% OLT=(V*HE*TT);%Multiply out Open Loop Transfer Function (PID excluded for OLTF) figure(5) Step(OLT); Bode(OLT) %%
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Kp=0.978; CLT=(Kp*V*HE*TT);%Multiply out Open Loop Transfer Function (PID excluded for OLTF) figure(13) Step(CLT,100); %% % Controller gain was calculated at max 4.954 before exceeding the % -180Degree gain margin and the loop becoming unstable Kp=1.09; CLT=(Kp*V*HE)/(1+(Kp*V*HE*TT)); %CLT=feedback(OLT,TT); %B1 = OLT; %B2 = TT; %B3 =feedback(OLT,TT); figure(7) step(CLT,200); %% OLT=(V*HE*TT);%Multiply out Open Loop Transfer Function (PID excluded for OLTF) figure(9) step(OLT); rlocus(OLT) %% Kp=0.978; Kd=0.5; CLT=((Kp*(1+Kd*s))*V*HE*TT);%Multiply out Open Loop Transfer Function (PID excluded for OLTF) figure(12) Step(CLT); %%rlocus(CLT)
42
%% Kp=1.13; Kd=0.5; CLT=((Kp*(1+Kd*s))*V*HE)/(1+((Kp*(1+Kd*s))*V*HE*TT)); %CLT=((Kp*(1+Kd*s))*V*HE*TT);%Multiply out Open Loop Transfer Function (PID excluded for OLTF) figure(13) Step(CLT,200); %rlocus(CLT) %% Kp=1.2; Kd=3.5; Ki=0.1; CLT=((Kp*(1+Kd*s+(Ki/s)))*V*HE)/(1+((Kp*(1+Kd*s+ (Ki/s)))*V*HE*TT)); %CLT=((Kp*(1+Kd*s))*V*HE*TT);%Multiply out Open Loop Transfer Function (PID excluded for OLTF) figure(261) Step(CLT,200); %rlocus(CLT)
%END OF SYSTEM MODEL As can been seen from the modelling plots the Algorithm for the boiler control using the BEEMS system works very well in Mathematical simulation. Unfortunately the time and cost constraints of this project do not allow the testing in practice of this algorithm. For this reason a lot of time was spent getting it fully modelled and simulated in MatLab. This demonstrates the concept principle. It was planned that Dundalk Institute of Technology would allow access to boiler plant to perform a deployment of the BEEMS system for energy efficiency testing. Written requests and proposals were submitted to the Estates department at the college and Tim Daly and Dr. Dan OBrien assisted greatly in negotiating access to a plant room. Initially it did not appear that this access would be granted. A contingency plan was formulated whereby TCD (Trinity College Dublin) had agreed to allow the project to be tested on one of their boiler
43
systems. The installation requirements were assessed during the interview process of with industry in semester 1. The plan was to fit 2 clamp on thermocouples and clamp on time of flight ultrasonic flow meters (1 for the hot water and 1 for the incoming oil or gas). This would allow a full test the boiler using the BEEMS system and the energy efficiency algorithm developed earlier (see page 26).
In order to proceed further with these works the following documentation would need to be put in place:
Insurances Training certification Health and Safety statements Risk Assessment for works Method statement for works
The pictures on Page 44 illustrate the plant room offered by TCD. However Dundalk Institute of Technology did grant access to their plant and the TCD site was not required. The pictures on Page 45 illustrate the plant room at DkIT which was assessed for these works.
Tim Daly (Engineering faculty) and Christian Maas (Estates Department) assisted in providing access to and use of the Boiler plant room. Christian was particularly helpful in determining the best way to approach the deployment of any equipment required.
44
Photos - Trinity College Boiler rooms at the McNamara Building
Photos from DkIT Boiler house - appraisal visit Tim Daly and Christian Maas alongside Duty and Standby Gas Boilers
Incoming gas flow meter (left) and Boiler output hot feed lines and pumps (right)
Proposed flow meter installation point and electrical control cabinet. Costings for the implementation of Boiler Energy Efficiency Testing 1 x DN100 Mag5100W flow meter sensor 1,700 + VAT 1 x Mag5000 Converter for flow meter 1 x Mag5000 remote mounting bracket and PCB 1 x Special fitting fabrication Sum Fitter to fit Flow meter and remove later VAT(estimated) 1,200 + VAT 220 + VAT
500 + VAT 800 + 300 + VAT
2 x PT100 clamp on temperature sensors (4-20mA) Sum Cable , cable tray, Thermal cladding Subtotal-1
100 + VAT 4,820 + VAT
Costings for the implementation of Fugitive gas with BEEMS system 1 x Special cable for Gas meter 100 + VAT (estimated)
45
1 x OLCT10 CH4 gas sensor 1 x CEX300 CO2 gas sensor 1 x CEX300-IR O2 gas sensor
200 + VAT 400 + VAT 800 + VAT
1 x slam shut valve (not required will use relay to mimic) Sum Calibration gases (N2, Clean Air, CH4, CO2) Subtotal-2 450 + VAT
1,950 + VAT
BEEMS system hardware costs (additional to either of above costs) 1 x DT85 Data logging module 2,000 + VAT 1 x UPS of system 1 x GSM modem for SMS alarms and control 12 x relays for Plant pump monitoring/trip reset Subtotal-3 50 + VAT 150 + VAT
240 + VAT
2,440 + VAT
The cost of implementing the boiler energy efficiency testing proved to be too expensive for the budget available. This was most unfortunate but unavoidable. However it was decided to still use the access granted to the Boiler plant room to carry out a deployment of the BEEMS system to prove the concept of fugitive gas monitoring and control. This will be discussed in the Fugitive Gas section (See Page 58).
46
TUMBLE DRYER ENERGY MANAGEMENT
THROUGH
BEEMS
Since the Boiler energy efficiency was too expensive to implement it was decided to find an alternative application to demonstrate the concept of using BEEMS for energy management purposes. Another project running at DkIT was an improved Tumble Dryer system that was more energy efficient than the standard model. Noel Rooney the student carrying out this work is a Mechanical Engineering student and was in need of assistance in collecting data on temperature, relative humidity , air flow and electrical energy in order to profile and compare the modified and unmodified tumble dryers. It is not within the remit of this report to detail the engineering differences between these 2 dryers, rather this report will detail the testing performed by BEEMS. Below is a picture of 2 identical tumble dryers manufactured by Creda. The machine on the left has been modified by Noel Rooney in order to achieve energy efficiency. The machine on the right is an unmodified dryer as built by Creda.
47
Testing Strategy
Diagram Copyright of Chris Pullen
In order to profile and compare the two machines each dryer was fitted with identical sets of sensors. BEEMS was configured to record data measurements from all measuring points at the following intervals: 1 second (mimic update -no recording), 10 seconds, 1 minute and 10 minutes.
48
The customer requested the following items to be logged: Parameter Ambient air intake temperature Drum temperature Vent temperature (exhaust air) Relative humidity Air velocity Phase voltage Phase current Time and date Clothes weight pre dry Clothes weight post dry Vent pipe CSA Sensor PT100 PT100 PT100 Handheld meter Handheld anemometer Voltage transducer Current transducer Data points stamped Weighing scales Weighing scales Vernier calipers
Derived Parameter Total Air Volume Time Total Electrical Power Kg CO2 reduction Energy cost
Sensor Vent CSA x Air Velocity x Voltage x Current x Time Kwh usage x CO2 Kg/kwh Kwh usage x cost/kwh
Both Machines were data logged in parallel meaning all of the above parameters were required for EACH machine.
49
Sensor and Transducer Installation
The Void, Drum and Vent Temperatures were monitored using PT100 sensors as shown in the pictures. The phase voltage and phase currents were monitored Handheld Instruments and BEEMS data logging using voltage and current transducers as shown in the pictures. The picture above illustrate the handheld instruments used during the Both machines were fitted with testing. Budget restrictions prevented the use of sensors, with signal independent equipment outputs suitable for data logging, for every parameter. Where simultaneously. handheld instruments were used readings were taken every minute Each Machine needed to be powered and entered manual into the BEEMS system where they were recorded with the other parameters. This was achieved by setting a list control variable values, representing the manually measured parameters, to the measured reading. The open source code in the DT85 Data-Taker data logger which was used to form the data acquisition basis of the BEEMS system allowed the CV values to be altered over a USB connection from a PC or Laptop. The software was written to record CV values labelled as the parameters measured with handheld instruments.
Data Analysis - Graphical Display (Mimics) for live test data
50
The above illustration is a screenshot of the mimics produced to allow the customer (in this case a student) to view graphically their process in real time. The mimics are a little crude but are more than sufficient to demonstrate the feature of real time mimics being used in conjunction with the BEEMS system. Improvements on the graphics quality is simply a matter of purchasing a professional quality drawing package. Any bmp or jpeg image is compatible with the BEEMS system software. Up to 256 icon images can be embedded into a mimics screen. The numerical values representing data channels are superimposed on top of the background or icon image. These overlays are basically channel number tags to tell the BEEMS software which channels value is to be printed to the screen, what font colour and size, what the name of the connection is (e.g. USB port 2) and how frequently to update the screen print.
Data Analysis - Trending modified-v-unmodified Vent Temperature
51
The data trending on page 54 was produced from the data that was collected from the testing of the Tumble Dryers. The customer was
52
very happy with the trending as it greatly simplified the analysis of the testing. This trend is just a sample of many trends produced for the customer. The trending was an important item to deliver on as it is kernel to the concept of using BEEMS as a tool for management and analysis. Similarly the customer feedback on the mimic screen was excellent as it allowed the customer to assess the energy efficiency testing in real time and to ensure that all monitoring equipment was working without having to wait until the test was completed. The next step was to demonstrate how the collected data could be used to analyse the energy efficiency of the tumble dryers. In order to do this a trend of the electrical power was produced to compare and contrast the energy usage of both dryers over the testing period. Again here the customer was extremely happy with the results. As can be seen from the trend on page 56 the BEEMS system data verified that the energy inputted into both machines was almost identical at 2.40 Kwh for the unmodified machine and 2.42 Kwh for the modified machine. So the energy into both machines has been quantified. The clothes inside were carefully matched to be the same material and weight. They had the same water content since the loads came from the same wash and spin. The next step to verify that the customer has identified how to save energy from the tumble drying is to compare the energies vented in the exhaust air. In other words how much electrical energy can be removed from the modified machine drying cycle and still maintain the heat levels in the vented air which is present in the unmodified machine (this difference being energy which was previously being lost through inefficiency). The illustration on page 57 is a screen shot of the BEEMS data being analysed in a spread sheet format. The vented hot air energy difference between the modified and unmodified machines is shown to be 9.5% higher on the modified machine. This proves that the customers modifications have verified that energy savings are possible with the Creda tumble dryer. The customer can reduce the heating element size or duty cycle in order to reduce the vented hot air energy by 9.5% without reducing the drying effectiveness of the machine. It was highlighted to the customer that the 9.5% energy saving which
53
appears to be possible should actually be in the region of 12% as the efficiency of inductive heating coils would be no better than 80%. Therefore reducing the energy into these heaters would yield an additional saving. The customer feedback from this portion of the project was very positive and it also allowed for the BEEMS system to be demonstrated to the project supervising Lecturers.
Data Analysis - Trending modified-v-unmodified Power Consumption
54
Data Analysis - Spreadsheet Masses
Power difference in Vented Air
Sample Open Source Code for Dryer Testing The software configuration for the BEEMS system is done via augmenting pre-existing code with open source code. The code for the IPPC licence configuration is not being published here as it is of significant commercial value. However the code for the tumbler dryer energy testing that has been outlined in this report is available in the appendix at the back of this report (see page 73). The code would bulk out the main body of the report unnecessarily. So it was felt the best place to include the code is in the appendix. The MatLab code was included in the reports main body because it was felt that the significant time spent on MatLab should be highlighted.
55
FUGITIVE GAS DETECTION
AND
ALARMING
USING
BEEMS
56
The above diagram shows the Fugitive Gas Management feature of BEEMS as indicated by the grayed box which is the third project goal. About Fugitive Gas Having obtained clearance to use one of the DkIT boiler rooms for BEEMS testing it was a disappointment when the Boiler Efficiency goal was found to be too expensive to implement. It was decided to instead use the boiler room for Fugitive gas emissions monitoring. Ideally it would be desirable to measure a suite of gases and use the BEEMS system to interpret the readings obtained to satisfy multiple monitoring requirements. CH4 (Methane) is a hydrocarbon gas burned as a fuel by boilers. The CH4 gas can escape and become a health hazard so CH4 monitoring is important from a health perspective as well as an explosion risk perspective. Although CH4 is colourless it does have an added odoriser for safety. However the nature of Hydrocarbon gas is that they act to anaesthetise the olfactory receptors in the nose even at very low concentrations. So the smell is only an effective indication of the presents of gas for a short initial period. CH4 is lighter than air and detection equipment should be suitably located at a high level within a confined space. Note: other hydrocarbon fuels commercially available such ad propane, butane or LPG (a mix of propane and butane) are heavier than air so detectors should be located no more than 0.3m above floor level. CO2 (Carbon Dioxide) is a by-product of the combustion process for all hydrocarbon fuels. CO2 is an asphyxiant and therefore is hazardous. CO2 is colourless and odourless. It is heavier than air and detection equipment should be suitably located at close to the lowest floor level in a confined space. CO (Carbon monoxide) is another by-product of the combustion of hydrocarbon fuels. The presents of CO can be particular problematic with badly services burners or badly ventilated flues. CO is colourless and odourless. It is highly toxic even at low concentrations as it bonds in a similar fashion to the haemoglobin in blood (causing the blood to become cherry red in colour). CO is slightly lighter than air so detectors should be mounted no higher than 4 foot from the floor (or lower where children are expected to be present).
57
O2 (Oxygen) is the second fuel required for the combustion of hydrocarbon fuels (or almost all fuels for that matter). O2 enrichment is a health hazard but by far the most common hazard with O2 is depletion. O2 levels below 17% can cause death. Even below 19% the body can become light headed and clumsy. This is itself a danger. O2 is colourless and odourless. It is slightly heavier than air. O2 detection equipment is often used for 3rd party detection. The idea behind this is that a drop in the O2 concentration in air is an indication of one of the following: combustion or oxidation are using up the O2 present in the air, or a 3rd party gas is present in higher than natural concentrations and is occupying some of the volume in air normally taken up by O2. O2 detectors are therefore located mid height in a confined space. The monitoring of fugitive gas in the DkIT using a BEEMS system could be employed to do any or all of the following:
Detect fugitive CH4 [Health and explosive risk] Detect elevated CO2 levels [Health risk] Detect elevated CO levels [Health risk] Detect depleted levels of O2 [Health risk and possibly indication of other gas] Monitoring if boiler burn becomes dirty Monitor if ventilation to burner becomes obstructed Monitor if ventilation of flue becomes obstructed Monitor for TWA (Time Weighted Average) exposure levels for personnel Monitor for STEL (Short Term Exposure Level) exposure levels for personnel Automatically activate slam shut vale on leak detection or limit exceedance
58
Automatically generate Alarms on leak detection or limit exceedance Report back live levels to personnel before confined space entry
Fugitive Gas Monitoring Setup
The photos above show the Fugitive gas detector fitted in the DkIT boiler room. A CH4 detector was installed close to the ceiling. An O2 detector was fitted at mid height in the room. A CO2 detector was fitted close to floor level and the DT85 was fitted in the Electrical control panel . Each detector was calibrated using bottles calibration gases applied at a flow rate of 0.5 litres per minute (as per manufacturers recommendations). The CH4 ,CO2 and CO detectors were Zero set using a pure Nitrogen (N2) gas. The CH4 was spanned using a 2.5% CH4 by Volume gas. The CO2 was spanned using a 2% CO2 by volume gas and the O2 was spanned using Analytical Air which has 20.9% O2 by volume. Each sensor had a 4-20mA output and the DT85 was calibrated against these current loop signals while the zero and span gases were ON (being applied to the detectors). Therefore the whole system was calibrated to industry standards using traceable gas. Data Analysis Trending of Boiler House Gas Data
59
60
The trend illustrated on the last page (62) shows the behaviour of the CH4, CO2 and O2 gas in the boiler house during the deployment of the BEEMS system. It is unremarkable since the boilers in this plant room are very well serviced. Only trace amounts of CH4 is present (see blue trend line) and a saw tooth pattern is discernable from the ON/OFF operation of the boilers. The CO2 trace (the red line) shows the natural background levels of CO2 (approx 400ppm) found in Air but with the CO2 produced by the boiler combustion superimposed. The CO2 trend tracks the CH4 trend since the extra CO2 is produced as a function of the operation of the Boilers and any trace CH4 is also a function of the boiler operation. The O2 trace (black line) shows 2 interesting trends. Firstly the Diurnal variation can be seen. The Diurnal variation is a natural variation in Oxygen levels found in Air between Day and night due to photosynthesis processes of plants and marine algae. The second trend that can be seen is again the boiler operation superimposed. Although the saw tooth feature of the CH4 trend cannot be seen there is a definite correlation between the average CH4 levels and the variation in the natural O2 profile. Although the data collected by the BEEMS system does not have include any risk events the capability of the system to accurately and precisely track the gas mix within the confined space has been very well demonstrated.
61
Back End (User end) software interfacing to BEEMS
62
The above diagram shows the Backend Software features of BEEMS as indicated by the grayed box which is the fourth project goal. The Backend software features required for the BEEMS system need to include at a minimum the following: Flexible connectivity Mimics and user interface Data trending Alarm Log / Reporting
Flexible connectivity The BEEMS system has an extremely flexible communications platform. Users can mix and match any of the following ways: Ethernet 10BaseT (10Mbps) o (TCP/IP protocol) o Web Server o FTP Server o FTP Client
USB (ASCII Protocol) Serial interfaces: o ModBus o RS232

o
RS422m
63
o RS485 o CAN Bus Local LCD display and panel buttons Front paned USB memory stick port
Mimics and user interface The BEEMS system mimic capability was demonstrated within the tumble dryer testing process. The capacity of the BEEMS system is 1900 channels per DT85 based hub. Larger systems are possible and DT85 hubs could be made swap information using ModBus. However there is a limitation with the User interface software if the system size exceeds 1 hub max capacity of 900 channels. In such a case the user would configure the software to send all the channel data to a database and then retrieve the data required from that database. This allows the system to be virtually limitless with regard to the number of channels. However it would cause the system to become more complicated as an extra data management layer is added. The response time of the Backend software would also be adversely effected. The user has a choice of presenting data in a mimic screen, a spreadsheet and a trending screen (graphing) as we have seen already. There are also further choices of a text screen (a scratch pad with updating text) and a web browser interface (the web server in
64
built into the DT85 but must be configured to suit the BEEMS application).
Example: Trending viewed through Internal Wed server mimic
Example: Live data viewed through internal web server mimic
65
Example: Data retrieve embedded into internal web server interface
Example: Channel Text listing viewed through internal web server
Data trending Historical data trending has been demonstrated throughout this report. Trending was produced for the IPPC licence BEEMS configuration, for the Energy efficiency BEEMS configuration and again for the Fugitive gas BEEMS configuration. The feature is well tested and proven. Live data trending is utilized as easily as historical trending. The only difference is the user selects a channel on a live connection rather
66
than one from a data file or database. Below are thumbnail views of trends used throughout this report.
67
Alarm Logging and Reporting Alarm logging and report generation are crucial features to ensuring the BEEMS system is commercially successful. In order to market the system as cost effective there must be a significant and quantifiable cost benefit. The more a system such as BEEMS can automate reporting and data management the lower the labour cost is to the end user. IPPC licensing is a very good case in point. The licence holder is legally bound to adhere to strict reporting formats and time scales as stipulated in the licence. IPPC licence holders must report an exceedance to the EPA within 48 hours of an occurrence. They must also generate reports based on hourly, daily, monthly, quarterly and annual limits. The BEEMS system can be configured to Alarm on high , low or complex limits for any parameter. These alarms are stored in an alarm log database and manual or automated reports can be generated. The user can tailor these reports to suit the EPA requirements by simply modifying the parameters and time scale of interest. The reduction in resources and costs required to meet reporting requirements are an attractive selling point and demonstrate again the sustainability benefits of this product. The EPA or licensing Authority can also save resources through reduced audit requirements, since the data management is a more secure format than manual data collection and manipulation. It is also possible for BEEMS to publish reports and data directly to a static IP address by means of TCP/IP push. This means that anyone interested in the data or reports need no special softwares. Anyone with a web browser and possibly a password can view the information. With industry heading more and more down the route of implementing Cloud computing topologies the BEEMS system is well placed to compete in the market place.
Example: Text Report file generated from logged data
68
Example: Alarm report automatically generated
69
LEGISLATION
AND FUNDING
Systems such as BEEMS will be mandatory in the near future. Already the European Parliament Directive 2002/91/EC imposes obligations on member states to legislate for new buildings to meet minimum Energy standards. Downward pressures in Europe and Ireland will lead to this obligation being levies on all commercial and eventually domestic buildings. The SEAI Energy Efficiency Retrofit Fund (EERF) allows commercial and academic facilities to apply for grant aid to carry out remedial works to make buildings more energy efficient and sustainable. In some cases up to 80% of the costs can be recouped. These documents are included in the Appendix (See Page 85 Section 5).
ACKNOWLEDGEMENTS
DKIT Lecturers / Staff:
70
Tim Daly, Pdraig McGuigan, Kimmitt Sayers, Dr. Dan OBrien Christian Maas Dr. Eoin Clancy Mark Clarke James Mulvany
DKIT Students Noel Rooney
Industry Contacts Edward Keating Uisce Technology Stephen Moran BOC Gases Aidan Corrigan IFM John Robinson Trinity College Dublin Michael Bergin Green Star Environmental Tom Butterly Dublin City Council Heating Department
I would also like to thank my family for their patience and support during my studies at Dundalk Institute of Technology. I also want to thank Omni Instruments for financing the project.
APPENDIX
Sample Open Source Code for Dryer Testing
'JOB=JOB1 'COMPILED=2011/04/04 00:24:41 'TYPE=DT85 DT=\d 6*PT385("M Void",W,=6CV) 56CV("M Void",=56CV)=6CV-1.22 7*PT385("C HE1 Pre",W,=7CV) 57CV("C HE1 Pre",=57CV)=7CV-0.97
71

BEGIN"JOB1" CATTN 'Spans and polynomial declarations S1=5.62,10.52,1.396,2.145"Amps" S2=0,238,7,14.2"VAC" S3=5.69,10.63,1.375,2.175"Amps" S4=0,238,0.49,14.24"VAC" 'Thermistor declarations 'Switches declarations 'Parameter declarations 'Global declarations RS1S 'schedule definition RA"LIVE" ("B:",ALARMS:OV:100KB,DATA:OV:1MB)5S LOGOFFA GA 1*PT385("U Drum",W,=1CV) 51CV("U Drum DegC",=51CV)=1CV-1.18 2*PT385("U Vent",W,=2CV) 52CV("U Vent DegC",=52CV)=2CV-1.68 3*PT385("U Void",W,=3CV) 53CV("U Void Deg C",=53CV)=3CV-1.13 4*PT385("M Drum",W,=4CV) 54CV("M Drum",=54CV)=4CV-1.46 5*PT385("M Vent",W,=5CV) 55CV("M Vent",=55CV)=5CV-0.97 8*PT385("C HE2 Pre",W,=8CV) 58CV("C HE2 Pre",=58CV)=8CV-1.21 9*PT385("C HE2 Post",W,=9CV) 59CV("C HE2 Post",=59CV)=9CV-1.06 10*PT385("C HE1 Top",W,=10CV) 60CV("C HE1 Top",=60CV)=10CV-1.08 11*PT385("C HE2 Top",W,=11CV) 61CV("C HE2 Top",=61CV)=11CV-1.01 12*PT385("C Vent",W,=12CV) 62CV("C Vent",=62CV)=12CV-1.24 15*PT385("Room Air",W,=30CV) 30CV("Room Air DegC",=31CV)=30CV-1.35 13HV(S1,"U Amps ",W,=13CV) ALARMR(13CV("U Amp Zero")<2.0000) {[13CV=0]} 13CV("U Amps") 14HV(S2,"U Volts",W,=14CV) 14CV("U Volts VAC") 14CV("U Volts VAC") 15CV("U Power Kw",=15CV)=((13CV*44CV)/1000) 35CV("U Power Kwh",=35CV)=35CV+(15CV/870) 15HV(S3,"M Amps",W,=70CV) ALARMR(70CV("M Amp Zero")<2.0000) {[70CV=0]} 70CV("M Amps") 16HV(S4,"M Volts",W,=17CV) 17CV("M Volts 0") 17CV("M Volts VAC") 91CV("U VEL M/S man") 92CV("M RH % man") 93CV("M VEL M/S man") 'schedule definition RC"5 min"("B:",ALARMS:OV:100KB, DATA:OV:1MB)5M LOGONC GC 51CV("U Drum DegC") 52CV("U Vent DegC") 53CV("U Void Deg C") 54CV("M Drum") 55CV("M Vent") 56CV("M Void") 57CV("C HE1 Pre") 58CV("C HE2 Pre") 59CV("C HE2 Post") 60CV("C HE1 Top") 61CV("C HE2 Top") 30CV("Room Air DegC") 15CV("U Power Kw") 35CV("U Power Kwh") 18CV("M Power Kw") 36CV("M Power KwH") 13CV("U Amps ave",AV) 14CV("U VAC ave",AV) 70CV("M Amps ave",AV)
18CV("M Power Kw",=18CV)=((70CV*47CV)/1000) 36CV("M Power KwH",=36CV) =36CV+(18CV/720) 90CV("U RH % man",=90CV) 91CV("U VEL M/S man",=91CV) 92CV("M RH % man",=92CV) 93CV("M VEL M/S man",=93CV) 'schedule definition RB"1 min"("B:",ALARMS:OV:100KB, DATA:OV:1MB)1M LOGONB GB 51CV("U Drum DegC") 52CV("U Vent DegC") 53CV("U Void Deg C") 54CV("M Drum") 55CV("M Vent") 56CV("M Void") 57CV("C HE1 Pre") 58CV("C HE2 Pre") 59CV("C HE2 Post") 60CV("C HE1 Top") 61CV("C HE2 Top") 30CV("Room Air DegC") 15CV("U Power Kw") 35CV("U Power Kwh") 18CV("M Power Kw") 36CV("M Power KwH") 13CV("U Amps ave",AV) 14CV("U VAC ave",AV) 70CV("M Amps ave",AV) 17CV("M VAC ave",AV) 90CV("U RH % man")
17CV("M VAC ave",AV)

90CV("U RH % man") 91CV("U VEL M/S man") 92CV("M RH % man") 93CV("M VEL M/S man")
'schedule definition RD"10 min"("B:",ALARMS:OV:100KB,DATA:OV:1MB)10 M LOGOND GD
72

51CV("U Drum DegC") 52CV("U Vent DegC") 53CV("U Void Deg C") 54CV("M Drum") 55CV("M Vent") 56CV("M Void") 57CV("C HE1 Pre") 58CV("C HE2 Pre") 59CV("C HE2 Post") 60CV("C HE1 Top") 61CV("C HE2 Top") 30CV("Room Air DegC") 15CV("U Power Kw") 35CV("U Power Kwh") 18CV("M Power Kw") 36CV("M Power KwH") 13CV("U Amps ave",AV) 14CV("U VAC ave",AV) 70CV("M Amps ave",AV) 17CV("M VAC ave",AV) 90CV("U RH % man") 91CV("U VEL M/S man") 92CV("M RH % man") 93CV("M VEL M/S man") END 'end of program file
DT85 Specification sheet
Full data specification downloadable at:
73
http://www.datataker.com/Library/Product_Data_Sheets_TS/TS-0067-E1%20%20DT85.pdf
Terms
BATNEC Cost BEEMS System BMS BOD
Best Available Technology Not incurring Excessive Building Energy and Environmental Management Building Management System Biological Oxygen Demand
74
BTU Cap-Ex CH4 CO COD CO2 CSA CSR CV DkIT EC EPA Ethernet EU Flume FSK Fugitive Gas plant leaks Glycol transfer. GSM GUI HMI HVAC Hydronic Internet INvironment I/O devices IPPC Klaxon
British Thermal Unit Capital Expenditure Methane Chemical symbol for Carbon Monoxide gas Chemical Oxygen Demand Chemical symbol for Carbon Dioxide gas Cross Sectional Area Corporate Social Responsibility Channel Variable Dundalk Institute of Technology European Community Environmental Protection Agency Ether (from Greek meaning Anywhere) Network European Union An open artificial channel used for flow gauging Frequency Shift Keying Pollutant released to air from equipment and An alcohol of 2 Hydroxyl groups, used for heat Global System for Mobile communications Graphical User Interface Human Machine Interface Heating, Ventilation and Air Conditioning Term to describe the transfer of heat by water Interconnected Network Indoor environment, term defined for this project Input /Output, used to describe field interface Integrated Pollution Prevention Control A loud siren used for raising alarms.
75
Kw Magmeter MatLab mg/l Modbus NVM OLE OPC Optoisolator OTS O2 PC PID PLC Potable ProfiBus PSTN PT100 @ 0C Qin / Qout flow RTU SCADA SCOM SDF SEAI Sewage Sewerage SHEQ SMS Solenoid
Kilowatt , unit of electrical power Magnetic flow Meter Software Package for Mathematical Modelling milligram per litre Modicon communications Bus Non-Volatile Memory Object Linking and Embedding OLE for Process Control Optically Isolated signal interface device Off The Shelf Chemical symbol for Oxygen gas Personal Computer Proportional Integral Derivate Programmable Logic Controller Water fit for human consumption Process Field Bus Public Switched Telephone Network Platinum Resistance device with resistance of 100 Flow in/Flow out, Q is notation representing a liquid Remote Telemetry Unit Supervisory Control And Data Acquisition Superimposed Communications Over Mains Secure Data Format Sustainable Energy Authority of Ireland Liquid and solid waste carried off in sewers or drains A system of sewers or drains to carry away sewage. Safety, Health, Environmental and Quality Short Message Service Magnetising coil powered by electric current.
76
Chris Pullen
STEL TBL a
Short Term Exposure Limit Triple Bottom Line, a term indicating the social, environmental and financial cost as opposed to solely financial cost (Bottom Line)
TCD TWL UPS USB
Trinity College Dublin Time Weighted Average Uninterruptable Power Supply Universal Serial Bus
77

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D ESIGN : B UILDING E NERGY AND E NVIRONMENTAL M ANAGEMENT AND C ONTROL S YSTEM

4th Year Sustainable Design Practical Final Report

Candidate: Chris Pullen Student Number: D00131950 Course Code: DK_ESUSD_8 Y4

Lecturers: Tim Daly Pdraig McGuigan Kimmitt Sayers

Student Number: D00131950