Energy Assessments of High-tech Facilities

National Energy Efficiency Conference

Singapore
William Tschudi
May, 2011
WFTschudi@lbl.gov
 hospitals

laboratories
 * First Energy Benchmarking for Labs, cleanrooms,
data centers publically available
* Research Roadmaps for High-Tech Buildings
* Demonstrations of Emerging Technologies

A 10-Year Industry Plan For High Tech Buildings

HIGH-PERFORMANCE
LABORATORIES and
A TECHNOLOGY
ROADMAP

CLEANROOMS

Developed by:
Lawrence Berkeley National Laboratory with input from industry partners representing high tech
facility design and operation, industry associations, research laboratories, energy consultants,
and suppliers to the high tech industry.
*
William Tschudi, Dale Sartor, Evan Mills and Tengfang Xu

Sponsored by:
The California Energy Commission
Public Interest Energy Research (PIER)

1
Large Energy Footprint
Continuous Operation
High Energy Intensity
Little Focus on Energy Efficiency
Common Infrastructure Opportunities
Process Energy Opportunities

*
Cleanroom: Data Center:
* Semiconductor/PV * Web hosting
* Biotech/Pharmaceutical * Co-location
* Automotive * Banks
* Defense * Research
* Healthcare/Medical device * Telecom
* Education/Research * Large impact in every other
major industry

*
* High Process Loads
* Uninterruptible Power
* Stand-by Generation
* HVAC
* Chilled water plants
* Reheat
* Free cooling
* Ventilation/air-change rates
* Combinations
* Data centers in labs or hospitals
* Cleanrooms (operating rooms) in hospitals

*
* Design Rules of Thumb – Lack of Science Based
Design and Operation Criteria
* Education – Awareness of Opportunities
* Lack of Public Benchmark Data
* Exempt from Building Codes
* Resources Applied to Process/Mission
* Lack of Integrated Monitoring and Control
* Redundancy Options
* Sizing Issues
* Capital Cost vs Operating Cost

*
 * Assessment evolution

* We always start with Benchmarking

* Energy end use and other attributes are determined
* Energy related observations help to determine best
practices which were then published
* Energy efficiency measures were cross-cutting across
various industries
* Data mining of additional collected information revealed
other opportunities
 * Assessment assumptions
* Process loads are constant over the testing period
* Loads representing less than approximately 5% of the total energy use
are ignored
* Envelope loads represent less than 5% of the total energy load
* Accuracy of measured data varies. A qualitative evaluation of the
accuracy is provided.
* Production metrics not collected (e.g. Product/watt)
* Existing energy use data from prior measurements, or available
through Building Management Systems are used with little or no
verification. Engineering evaluation of this data, including its accuracy,
included during reporting.
* Where direct measurements cannot be obtained, values can be based
upon design numbers, other engineering calculations, or engineering
judgment.
* First establish baseline energy benchmarks for similar
facilities
* Establish assessment goals – e.g. energy, environmental
conditions, health and safety, etc.
* Develop assessment plan with facility owner/operator
* Sampling or full monitoring
* Time duration – snap shot or long term
* Extent of monitoring equipment
* Similarity exists between facilities/ industries but each
is unique

*
* Orient site staff
* Review design documents to determine energy
monitoring points
* Review existing monitoring capabilities
* available monitoring points
* accuracy
* Plan for additional data points
* Temporary or added electrical or environmental
monitoring
* Use of balance reports
* Use of design values
* Use of manufacturer’s data

*
* Collect energy and environmental data

* Analyze and reduce data

* Compare metrics to existing benchmarks

* Compare metrics to best practices

* Develop energy efficiency measures

* Known best practices
* Unique solutions (e.g. use of waste heat)

*
* 1. Getting Started- Identify Benchmarking Goals
* 2. Orient IT and Facilities Staff
* 3. Obtain Documentation
* 4. Create Site-Specific Monitoring Plan
* 5. Obtain Monitoring Equipment
* 6. Install Monitoring Equipment
* 7. Collect Data and Remove Monitoring Equipment
* 8. Analyze and Reduce Data
* 9. Compare Findings to Existing Benchmarks
* 10. Compare Data Center to Best Practices
* 11. Share Results

*
* 24 X 7 Operation
* Systems unable to be shut down
* Redundant components can be shut down to install
monitoring equipment
* Varying levels of monitoring exist through building
management systems
* No production impact
* Cleanroom protocol observed
* Safety programs followed
* Monitoring plan approved by management
* Assessment team must be experienced with production

*
 * Energy intensity (W/sf)
* Energy end-use
* HVAC
* Electrical
* Process
* Other
* Environmental benchmarks
* Additional data

*
 *
Recirculation System Efficiency
2.0
1.8 Averages
FFU: 0.63
1.6 Ducted HEPA: 0.58
Power Intensity (W/cfm)

Pressurized Plenum: 0.43

1.4 Overall average 0.49
(Lower is better)

1.2
1.0
0.8
0.6
0.4
0.2
*****
0.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Cleanroom ID
* Recirculation efficiency could not be measured for
21-24. System consisted of central air handler and
fan-filter units cascading through four rooms.
 Similar benchmarks for
cleanrooms or data centers

Chilled Water System Comparison

1.8
Cooling Tower
1.6
kW /Ton (Lower is better)

CW Pumps
1.4 CHW Pumps
Chiller
1.2
1
0.8
0.6
0.4
0.2
0
Water Air Cooled Air Cooled Air Cooled Air Cooled Water Water Water Water Water
Cooled 42°F 42°F 40°F 48°F 50°F Cooled 40°F Cooled 38°F Cooled 36°F Cooled 44°F Cooled 43°F

Facility A Facility B.1 Facility B.2 Facility B.2 Facility B.2 Facility C Facility D Facility E.1 Facility E.2 Facility F
Cleanrooms Cleanrooms Cleanrooms Cleanrooms Cleanrooms Cleanroom Cleanroom Cleanroom Cleanroom Cleanrooms
1,2 3,4 5,6 5,6 5,6 7 8 9 10 11,12,13,14

Facility ID
Cleanroom air velocity through
HEPA filters
 Comparison of cleanroom class – large variations

ISO Class 5 Cleanrooms

700

600
Air Changes per Hour

500

400

300

200

100

0
2 3 4 5 6 7 9 10 15 17 21 24
Cleanroom ID
* By working with International Sematech, air
velocities were lowered from 90 ft/min which was
the defacto standard to 65 ft/min with no adverse
effects.
* Air flow set-back was investigated in two case
studies. In one, a timer was used to slow airflow
during unoccupied night time and weekend hours.
In another, particle counters were used to directly
control fan speeds. Both strategies resulted in large
fan energy savings.

*
 *

*Based Solely on timeclock,

8:00 PM -6:00 AM setback
*No reported process
problems or concerns from
process engineers
*60% – 70% Fan power 25.00
RAH-Z Power

reduction on turndown Total kW

20.00

15.00
kW

10.00
Chan. 1
Chan. 2
Chan. 3

5.00

0.00

4 0:00 4 0:00 4 0:00 4 0:00 4 0:00 4 0:00 4 0:00 4 0:00

3/15/0 3/16/0 3/17/0 3/18/0 3/19/0 3/20/0 3/21/0 3/22/0 3
Date
Data Center electrical density
Similar assessment results for
cleanrooms or data centers

Measured UPS
UPS efficiency
Efficiency
100

80
Efficiency (%)

60

40

20

0
0 20 40 60 80 100
Load Factor (%)
 Assessments confirmed research

Benchmark results
UPS Efficiency
100

80
Efficiency (%)

60

Factory Benchmarks
40

20

0
0 20 40 60 80 100
Load Factor (%)
* Wireless sensors facilitate assessments
*
ASHRAE and the Green Grid
collaborated to develop a
measurement book to explain
energy measurements in data
centers
 *
* Assessment tools developed by the US Department of Energy’s Save
Energy Now program are available for public use.
* The Green Grid organization is collaborating and providing content
for the IT portions of the tools.
* An assessment process is described along with a suggested report
format.
* The assessment tools are collectively called DC Pro.
* Download the tools here:
http://www1.eere.energy.gov/industry/datacenters/software.html
 *
* Profiling Tool: energy profiling and tracking
* Establish PUE baseline and efficiency potential
* Document actions taken
* Track progress in PUE over time
* Assessment tools: more in-depth site assessments
* Suite of tools to address major sub-systems
* Provides savings for efficiency actions
* ~2 week effort
 *
High Level Profiling Tool
• Overall energy performance (baseline) of data center
• Performance of infrastructure & IT systems compared to benchmarks
• List of energy efficiency actions and their potential savings
• Tracking capability
• Points to more detailed system tools

IT Module Cooling Air Management Electrical

• Servers • hot cold Systems
• Air handlers/
• Storage separation • UPS
conditioners
• Network • environmental • Transformers
• Chillers, pumps,
fans conditions • Lighting
• Software
• Free cooling • Motors
• Simulation • Standby gen.
* US Department of Energy developed a program to
encourage energy assessments of data centers.
* DCEP provides a structured qualification process to
provide assurance of the assessor qualifications
* Prerequisites
* Training based upon DC Pro tools
* Exam
* Certificate
* DOE licensed the program administration to Data
Center Dynamics in the US and CNET world wide
* Learn more here:
http://www1.eere.energy.gov/industry/datacenters/
dc_cep.html
*
Bill Tschudi
wftschudi@lbl.gov
http://hightech.lbl.gov