Fault Detection and Diagnosis Process for Oversizing Design on Multiple Packaged Air-conditioning Units

Heating, ventilation, air-conditioning and Refrigeration (HVAC&R) systems are seldom designed or commissioned properly. The situation leads to abrupt or degradation faults resulting in inefficient energy uses, excessive energy consumption and high service costs. To solve these aforementioned problems, fault detection and diagnosis (FDD) is utilized to firstly detect any abnormal conditions of a system and then diagnoses and determines their causes. In order to apply this concept in HVAC oversizing designs, this paper proposes the state-of-art procedure of a FDD procedure for analyzing the inherently faulty design (oversizing) of multiple packaged air-conditioning units used to supply cooling for an open space in light commercial buildings. A generic process of FDD for a packaged unit is briefly introduced to efficiently design FDD algorithms and to illustrate an overview picture for new researchers in FDD areas. In the procedures, compressor statuses, time-on and time-off operations and outdoor air temperatures are recorded by means of the on-board controller of each machine unit. These physical and electrical monitoring data are applied to diagnose and evaluate oversizing level in terms of runtime fraction (RTF) and cycling rate (N). Eventually, an adaptive control is designed and implemented to enhance process recovery for soft-repairing and permanently reducing fault effect caused by oversizing without intervening system operations (non-invasive technology)

Development of Coordination Control for Multiple Rooftop Units

Rooftop Units (RTUs) have been widely applied in providing space heating and cooling for commercial buildings. In total, they serve over 60% of the commercial building floor space in the U.S. Even through the current control approaches of a RTU can maintain the zone temperature corresponding to a set point temperature, it performs inefficiently due to several factors such as limited sensing capability, non- coordinated local control, inherent oversizing effects and so on. In addition to unnecessary power consumptions, the current control and operation technology on RTUs also lead to the space humidity problem, equipment efficiency degradation, and premature failure. To solve aforementioned problems and enhance the overall system performance, this paper presents the development of a coordination control technique for improving the system operations of multiple RTUs used in light commercial buildings with an open space. In the control algorithm, simplified building models were developed to potentially estimate the instantaneous building load. Utilizing this model-based technique, sequence control strategy is designed to automatically select suitable mode operations of a RTU including economizing, heating, cooling and ventilation mode while synchronizing with the supply fan control and damper operations. Using a developed building simulation platform implemented on Matlab software, the developed coordination control is applied in reducing energy penalty caused by an inherent oversizing problem on multiple RTUs. With the findings, the control algorithm can be further used as a soft-repair for temporally fixing faulty operations and improper commissioning of multiple RTUs such as excessive or insufficient air flow, outdoor air leakage, stuck dampers and simultaneous heating and cooling (RTU fighting)

Virtual surface temperature sensor for multi-zone commercial buildings

Multi-zone structure is commonly used in small commercial office buildings, retail stores and supermarket. While there is no adjacent wall between the zones, the impact of a neighbor zone on the current zone can be approximated and analyzed through the application of virtual walls. It is critical to accurately estimate the virtual wall surface temperature in order to evaluate the model uncertainty and apply improved supervisory control on multiple rooftop air-conditioning units (RTUs). We propose an innovative virtual surface temperature sensor based on system-identification to solve this challenge. The validation of the virtual temperature model is processed by the three validation criteria: goodness of fit (G), mean squared error (MSE) and coefficient of determination (R2) through off control conditions with data obtained from a building simulation platform. Further, the sensitivity analysis using the on-control three conditions (under-sizing, properly sizing and oversizing condition) is conducted for analyzing and evaluating the performance of this system-identification based virtual sensor

A thermo-activated wall for load reduction and supplementary cooling with free to low-cost thermal water

A building envelope serves as a thermal barrier and plays an important role in determining the amount of energy used to achieve a comfortable indoor environment. Conventionally, it is constructed and treated as a passive component in a building thermal energy system. In this article, a novel, mini-tube capillary-network embedded and thermal-water activated building envelope is proposed to turn the passive component into active, therefore broaden the direct utilization of low-grade thermal energy in buildings. With this proposed approach, low-grade thermal water at a medium temperature close to the ambient environment can be potentially utilized to either counterbalance the thermal load or indirectly heat and cool the space. With the revealing of the idea, effects of water temperature and flow rate on the envelope’s thermal performance are investigated using a transient model. The results indicate that the thermo-activated wall can be effective in stabilizing the internal surface temperature, offsetting the heat gain, and supplying cooling energy to the space in summer. Utilization of the innovation should take the cost of total energy, energy benefit and efficiency into consideration. This article illustrates how low-grade energy can be actively used as a means for achieving net-zero energy buildings

Soft-repair technique for solving inherent oversizing effect on multiple packaged air-conditioning units in commercial buildings

Rooftop packaged air-conditioning units (RTUs) have been intensively utilized in commercial buildings for providing space heating and cooling. They serve over 60% of the commercial building floor space in the U.S. Inefficient routine operations of multiple RTUs result in waste energy consumption. Specifically, oversizing is an inherent issue practically caused by overdesign of mechanical engineers. With field test studies, oversizing can be up to 100% leading to much energy penalty. Although there are locally advanced control technologies utilized to improve the overall efficiency performance of RTUs, they are invasive approaches to interrupt normal operations and require experienced service teams for preventative maintenance causing high first cost installation and service costs with returning on investment (ROI) being more than 3-5 years depending on the type of a building. To reduce ROI and permanently reduce inherent oversizing issue without intervention of an original system, the report proposes a non-invasive methodology for reducing energy penalty caused by non-optimal design. The technique will use adaptive control strategies to minimize the fault impact until the receipt of actual physical repair or to ultimately eliminate the fault without any further physical intervention. Control algorithms are systematically developed to mainly reduce oversizing effect utilizing simplified instantaneous building load. With the control algorithm implemented and tested by a building simulation platform, the oversizing effect is decreased at least 30% and can be reached to 60%. With the decrease of the oversizing effect and energy penalty without original system interference, the improved results lead to: 1) compressor energy savings between 15 and 30% and fan energy savings between 30 and 55% and 2) improved indoor relative humidity resulting in more energy savings for commercial supermarket applications. The proposed method will be further applied to: 1) temporarily minimize the fault impact caused by faulty operations and improper commissioning such as over-circulation and outdoor damper leakage and 2) temporarily disabled severe faults including fail compressor, fail heater and some control-related faults meanwhile the overall performance of a system is in acceptable thresholds until these faults are physically fixed and ready to use normally

Fault Detection and Diagnosis Process for Oversizing Design on Multiple Packaged Air-conditioning Units

Heating, ventilation, air-conditioning and Refrigeration (HVAC&R) systems are seldom designed or commissioned properly. The situation leads to abrupt or degradation faults resulting in inefficient energy uses, excessive energy consumption and high service costs. To solve these aforementioned problems, fault detection and diagnosis (FDD) is utilized to firstly detect any abnormal conditions of a system and then diagnoses and determines their causes. In order to apply this concept in HVAC oversizing designs, this paper proposes the state-of-art procedure of a FDD procedure for analyzing the inherently faulty design (oversizing) of multiple packaged air-conditioning units used to supply cooling for an open space in light commercial buildings. A generic process of FDD for a packaged unit is briefly introduced to efficiently design FDD algorithms and to illustrate an overview picture for new researchers in FDD areas. In the procedures, compressor statuses, time-on and time-off operations and outdoor air temperatures are recorded by means of the on-board controller of each machine unit. These physical and electrical monitoring data are applied to diagnose and evaluate oversizing level in terms of runtime fraction (RTF) and cycling rate (N). Eventually, an adaptive control is designed and implemented to enhance process recovery for soft-repairing and permanently reducing fault effect caused by oversizing without intervening system operations (non-invasive technology)

Virtual Partition Surface Temperature Sensor based on Linear Parametric Model

Multi-zone structure is common in commercial office buildings, retail stores and supermarkets. Because there is no physical partition between zones, there could exist significant thermal impact among the adjacent zones than in other commercial buildings. It is critical to accurately analyze the energy interaction and reduce the modeling uncertainty for supporting advanced control. We propose a virtual partition surface temperature sensor for quantifying the variables and solve this challenge by using linear parametric models. The derived models based on physical law can be used as a guideline on selecting appropriate orders in mainly ARMAX (autoregressive moving average with exogenous variables) and/or ARX for improving the sensor’s performance. Validation of the virtual temperature models is conducted by three validation criteria: goodness of fit (G), mean squared error (MSE) and coefficient of determination (R2) under off-control conditions. The validation results show that the physical model based linear parametric model, ARX 211, performs well and similar to other system identification models, such as ARMAX 2111 and ARX 221, for estimating surface temperatures. The sensitivity analysis using three on-control conditions (under-sizing, proper-sizing and over-sizing condition) is conducted for analyzing and evaluating the performance and barriers of this virtual sensor. The proposed easy-to-implement model can be applied to support supervisory control of equipment in multi-zone buildings and other applications to supplement the measurements, like estimating the temperature of a structure integrated cooling or heating application in renewable energy areas

A thermo-activated wall for load reduction and supplementary cooling with free to low-cost thermal water

A building envelope serves as a thermal barrier and plays an important role in determining the amount of energy used to achieve a comfortable indoor environment. Conventionally, it is constructed and treated as a passive component in a building thermal energy system. In this article, a novel, mini-tube capillary-network embedded and thermal-water activated building envelope is proposed to turn the passive component into active, therefore broaden the direct utilization of low-grade thermal energy in buildings. With this proposed approach, low-grade thermal water at a medium temperature close to the ambient environment can be potentially utilized to either counterbalance the thermal load or indirectly heat and cool the space. With the revealing of the idea, effects of water temperature and flow rate on the envelope’s thermal performance are investigated using a transient model. The results indicate that the thermo-activated wall can be effective in stabilizing the internal surface temperature, offsetting the heat gain, and supplying cooling energy to the space in summer. Utilization of the innovation should take the cost of total energy, energy benefit and efficiency into consideration. This article illustrates how low-grade energy can be actively used as a means for achieving net-zero energy buildings

A Review of Fault Detection and Diagnosis Methodologies on Air-Handling Units

Faults occurring in improper routine operations and poor preventive maintenance of heating, ventilating, air conditioning, and refrigeration systems (HVAC&R) equipment result in excessive energy consumption. An air-handling unit (AHU) is one of the most extensively operated equipment in large commercial buildings. This device is typically customized and lacks of quality system integration, which can result in hardware failures and controller errors. This paper aims to provide a systematic review of existing fault detection and diagnosis (FDD) methods for an AHU therefore inspire new approaches with high performance in reality. For this goal, the background of AHU systems, general FDD framework and typical faults in AHUs, is described. Ten desirable characteristics used in a review of FDD in chemical process control are introduced to evaluate the methodologies and results. A new categorization method is proposed to better interpret the different and most recent approaches. The main FDD methodologies and hybrid approaches are described and commented to illustrate the use of evaluation standard parameters for improving the performance of FDD on AHUs