MSCM Case Study: Schedule Integration Saves Energy Through Automation
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Physical Plant Manager, Jeff Goebel, describes his team's efforts to reduce energy use and eliminate redundant data entry related to scheduling HVAC and security systems at the University of Minnesota Moorhead. This integration has resulted in a savings of $1 million in energy costs per year.
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MSCM Case Study: Schedule Integration Saves Energy Through Automation
- 1. Schedule Integration A Minnesota State University Moorhead Case Study MnSCU IT Conference, April 24, 2012 Jeff Goebel, Physical Plant Manager, MSUM 1
- 2. MSUM Institution Profile 140 acres 39 buildings, 1.8 million sq. ft. 7,486 students 789 employees Operating budget: $80 million 2
- 3. Aerial View - Sept 2010 3
- 4. Campus Systems Campus Security (door locks) Security Honeywell Johnson Controls Security 113 card readers 135 card readers Campus AHUs Variable Air Constant Multi-zone Dual Duct Residential Volume Volume Furnace 22 60 19 2 43 Campus Chillers Serving Serving Chiller’s Muliple Individual Eliminated Blds Blds since 2008 4 6 7 4
- 5. Campus Systems Campus VAVs Honeywell VAVs Johnson Controls VAVs CB 53 vav, 21ftr HAG 77 vav CMU 72 vav Wellness 28 vav FF 42 vav Kise 12 vav Lom 16 uh, 37 ftr, 77 vav MAC ftr, 66 vav MUR 17 vav 17,000 DDC Points 4,000 DDC Points 5
- 7. The Problem Poor energy efficiency across campus Most systems operated 14-18 hours per day Energy consumption (2008): 163 kBTU/sq. ft. Restricted budget Redundant, time consuming data entry 7
- 8. The Opportunity Event Management System Dean Evans EMS® Low classroom use Average of 17% campus-wide Opportunity to link to HVAC, lighting, 8 and door controls
- 9. The Solution • Update systems to direct digital 1 control • Integrate Systems with 2 Honeywell EBI® • Implement demand-limiting load 3 shedding • Implement Events2HVAC™ 4 9
- 10. 1. Direct Digital Control Pneumatic Control Assumes AHU Control on/off No remote control of Zone Some “night setback” control air pressure Early DDC (30-40 years old) Major systems only Chillers, AHUs, Pumps, Boilers No communication between different manufacturers Modern DDC supports open protocol 10 Zone Control for individual rooms
- 11. 2. Honeywell EBI® Integrate various legacy and vendor systems to open protocols and data formats 3rd Parties can consume data for enterprise reporting 3rd parties can integrate systems for energy efficiency Events2HVAC Demand Limiting – Load Shedding 11
- 12. 3. Demand-Limiting Load Shedding Predicts demand peaks Sheds loads to control demand peaks Lowers energy usage on high demand days Lowers energy 12 rates
- 13. 4. Events2HVAC™ Saves energy in unoccupied rooms Eliminates redundant data entry Adjusts dynamically to changing 13 schedules
- 14. The Results 14
- 15. The Results Energy Costs (per calendar year) 2008 - $3,049,397.28 2009 - $2,433,060.04 2010 - $2,197,778.18 2011 - $2,172,289.00 Labor Hours 2009 - 12 hours/week on scheduling 2011 - 2 hours/week monitoring systems 15
- 16. The Results Reducing errors Remove human factor Notification if command doesn’t execute Increasing efficiency Environment Changing focus 16 Repairs
- 19. Network Infrastructure HVAC and Access Control systems on existing network, a private VLAN with restricted ACL (Access Control List) Honeywell/EBI, JCI, and EMS servers in Data Center with 24/7 monitoring, UPS/Generator Backup Public Safety dispatchers on staff 24 hours a day, monitoring events related to the Access Control systems 19
- 20. Network Communication Eliminate Honeywell XL+ Controllers (1970s) Replace with Honeywell XL5000 Controllers Central integration point (Honeywell EBI) Common open protocol (BACnet/IP) Events2HVAC interface for JCI P2000 (XML/RPC) 20 XML/SOAP web services used for JCI
- 21. Training Honeywell Training EBI Building Energy Manager CARE Controller Programming Johnson Controls Training Controller Programming Door System Administrator Niagara Certification 21
- 23. Events2HVAC Preparation Get Network Ready Locate a server that can talk to both sides Make sure HVAC network can be seen Allow access to other systems (database, passwords, VPN) Get all players involved (HVAC, IT, scheduling, management) Equipment Definitions Equipment to be scheduled (AHU, VAV, etc.) Rooms to be mapped to equipment Actions during events (start/stop, lock/unlock, chg setpoints) Administrator and Users Roles 23 E-mail address for alerts
- 24. Events2HVAC One-Time Setup 1. Define equipment JCI AHU-1 Room A door access Room B VAV box 2. Map equipment to rooms AHU-1 Room 1, 2, 3 Room A door access Room A VAV Room B 24
- 25. Events2HVAC One-Time Setup 3. Create actions AHU-1 Start/stop on setup/teardown FC-2 Start/stop and adjust temp on event 25
- 26. How Events2HVAC Works 1 ONE TIME SETUP 3 ACTIONS SCHEDULED AND EXECUTED Defined EMS Actions Event Start Event #1 Daily Room A Actions Event Stop Events2HVAC 2 Server Setup Start BOOK EVENTS IN EMS Event #2 Room B Teardown Stop Daily Report Email 26
- 27. Events2HVAC Interfaces • Event Scheduling Software • Dean Evans EMS ® (All versions) • CollegeNET ® R25® • EmergingSoft MeetingPlanner (Microsoft Exchange/Outlook) • ministrEspace • Building Automation Systems • BACnet • Johnson Controls MSEA • Johnson Controls P2000 Security • NetworkThermostat 27
- 28. E2H Scheduling Data • Events/Year = 50,000+ • Average Occupancy Rate = 12% • Events2HVAC commands/day = 250-750 • Rooms scheduled = 327 • Direct VAV room control = 300,000 sqft 28
- 29. E2H Resource Links • Equipment Utilization Spreadsheet • BACnet Explorer • E2H Screenshot • Command Queue • Event Calendar • Equipment Command Report • Daily Event Report 29
- 30. Obstacles, Surprises and Custom Features 30
- 31. Obstacles City synch signal lost during storm Turned feature on, broke something 31 else
- 32. Surprises Custodial staff spends less time cleaning classrooms locked between classes People outside campus asking why rooms they have used for meetings are locked More campus activities properly monitored via the campus scheduling system 32 Changing the “campus culture” to a
- 33. Custom Features “Lockdown,” locks doors and disables cards for both JCI & Honeywell “Emergency Fan Shutdown,” currently by skilled operator client software – soon to be part of Fire Control Software usable by Public 33 Safety Dispatcher
- 34. Questions? 34
Editor's Notes
- Here are some figures to give you a feel for the size and scope of the MSUM campus and operations.I’m going to present energy saving improvements that we’ve made since 2008.
- Our campus systems include a variety of older legacy systems and more modern systems and equipment.
- Example: MSUM considers a classroom that is occupied 32 hours/week to be 100% utilization. But campus-wide, total occupation was approximately 17%, and some rooms were used less. But they were heated and cooled during the day when unoccupied.
- Our solution was really four related solutions.1. Update systems to direct digital control2. Integrate systems with Honeywell EBI®3. Implement demand-limiting load sharing 4. Implement Events2HVAC.I’m going to explain each of these related solutions in turn.
- Describe what direct digital control is and how it relates to the whole solution.Pneumatic Zone Control is unable to be remotely controlledAssumes energy demand is controlled at the AHUDDC Control comes on the scene in 30-40 years ago. Typical systems controlled large equipment, AHU’s, Chillers, Boilers, Pumps etc.Zone Control typically still pneumaticMSUM has 16,000 points
- Describe what EBI does and the importance of Honeywell EBI to the whole solution.
- Describe what demand-limiting load shedding is, its importance to the whole solution, and what this screen capture shows.
- Events2HVAC is a “bridge” software than links event schedules directly to HVAC, security, and lighting. It automatically sends commands to building equipment assigned in the system, turning them on and off based on individual room schedules. So when rooms are not scheduled to be in use, equipment returns to unoccupied settings, saving energy. Once Events2HVAC is setup, it works behind the scenes and eliminates the need for manual scheduling of equipment.
- After implementing Events2HVAC in 17 buildings on campus with 350 rooms, MSUM began saving energy and labor expenses. Today, academic schedules are loaded into the room reservation software at the beginning of each term, and events in common areas such as the student union are added daily. Events2HVAC automatically pulls data from the room reservation software daily, and automatically sends commands to control air conditioning, heating, lighting and door locks for individual rooms.
- Using BACnet and Honeywell’s text messaging of critical alarms – specific people get specific alarms
- This is a diagram of our current control system network. When examining potential critical failures, we discovered that if EBI Energy Manager fails during a peak demand, everything would run. So we will put in a back-up server that will be ready at all times so can automatically switch over to it if the main server fails.We are also working on server virtualization to shrink down physical hardware.
- We utilize our existing network infrastructure to provide connections to the various components that are encompass our system. This allows us to provide rapid integration of these systems as buildings are upgraded.
- We also had to make some changes to improve communication across systems. For example, we had some old Honeywell XL+ Controllers from the 1970s that required Honeywell personnel to program them. We were able to trade them in and get a good trade value, while replacing them with Honeywell XL5000 Controllers that can be campus programmed.Also, since Honeywell doesn't offer a BACnet interface for their door control system, we purchased a Honeywell EBI Distributed Server to serve the door system out to a BACnet Server. EBI serves as a central communication hub, translating proprietary points out as BACnet.Similarly, the JCI Door System doesn't talk BACnet. So Streamside Solutions developed a new interface for Events2HVAC so it can communicate with JCI door controllers.JCI MSEA controllers talk both BACnet/IP and also using web services. Web services was chosen for these controllers in order to exercise that specific interface for testing.
- In order to successfully implement the four pieces of the desired solution, we needed some additional technical skills. We sent team members to several training programs offered by Honeywell and Johnson Controls. (Say more about the importance of the training.)
- In advance of installing Events2HVAC, we had to gather some information and make some decisions about how it would operate. We had to determine exactly which pieces of equipment would be controlled by Events2HVAC, which rooms each piece of equipment were assigned to, and what temperatures we wanted to use for occupied and unoccupied settings. We also had to determine if we wanted to put in lead times for rooms to heat-up or cool-down before events started or after they ended – and how long those time periods should be.We had to identify the administrator and users for Events2HVAC, and gather e-mail addresses for any of them that might need to be alerted when specific equipment did not turn on or off correctly.
- Events2HVAC requires a one-time setup that can take a few days, depending on how many rooms and how much equipment is linked to the system and how well you gathered the necessary information ahead of time. The first two steps of the setup are to define equipment and map equipment to specific rooms.In naming equipment, consider naming conventions and number of characters. Example, Johnson Controls naming convention allows 120 characters, Honeywell only 48.We did find some shortcuts for this process. For example, you can open JCI Metasys front end (client) & paste points directly into Events2HVAC. You can also use BACnet Explorer (provided in Events2HVAC package) to paste Honeywell points into Events2HVAC.
- The third and final step of the basic setup for Events2HVAC is to create specific actions for each piece of equipment. Events2HVAC has several available options so that you can allow for event setup and teardown time if that is necessary.
- This diagram shows how Events2HVAC WorksFirst, events are booked in the event management software as usual. In our case class schedules are dumped into Dean Evans EMS at the beginning of each term, and other events are scheduled on a weekly and daily basis for facilities such as the student union.Then, Events2HVAC automatically commands the equipment based on room schedulesIt queries EMS at regular intervalsOptimizes schedules for each equipment itemActions are queued for executionFailures can be sent via emailCan send out daily reports via email
- Events2HVAC is compatible with four event scheduling systems, Dean Evans EMS, CollegeNET R25, EmergingSoftMeetingPlanner which works within Microsoft Outlook, and ministrEspace. Interfaces for additional scheduling systems are in development.On the building automation side, Events2HVAC is compatible with systems that use BACnet protocols, which are available from almost all manufacturers, as well as several other systems. Additional interfaces might be developed in the future.
- Events2HVAC is compatible with two event scheduling systems, Dean Evans EMS and CollegeNET R25. Interfaces with additional scheduling systems are currently in development.On the building automation side, Events2HVAC is compatible with systems that use BACnet protocols, which are available from almost all manufacturers, as well as several other systems. Additional interfaces might be developed in the future.
- Events2HVAC is compatible with two event scheduling systems, Dean Evans EMS and CollegeNET R25. Interfaces with additional scheduling systems are currently in development.On the building automation side, Events2HVAC is compatible with systems that use BACnet protocols, which are available from almost all manufacturers, as well as several other systems. Additional interfaces might be developed in the future.
- Talk about obstacles you faces and how you overcame them.-EBI bacnet server not configured correctly initially. This created unnecessary BACnet traffic and occasional timeout errors. Also some legacy honeywell controllers were occasionally going offline to the EBI.