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Exposure Control Technologies, Inc.

Copyright ©2018

5/31/2018

May 2018 Copyright © 2018


919-319-4290

[email protected]

Thomas C. SmithPresident

SMART LABS™️ - Roadmap to High Performance Laboratories

Hoy Bohanon Engineering, PLLC336-972-1626

[email protected]

Hoy Bohanon, PEPresident


Hoy Bohanon

Hoy Bohanon, P.E., is owner of Hoy Bohanon

Engineering, PLLC. During his 43-year engineering

career, Mr. Bohanon has run his own consulting

engineering business and worked at manufacturing

corporations as a product design engineer, project

engineer, facilities engineer, facilities manager, indoor

air quality researcher, and environmental engineer.

He has published and presented numerous papers and

articles on indoor air quality and serves as chair of

ASHRAE SSPC 62.1, Ventilation for Acceptable Indoor

Air Quality.

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Research is SERIOUS Work


Labs are specially designed to provide safe and

controlled environments that promote science

Hazards

• Chemical

• Biological

• Radiological

• Physical

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°T

dPdP

The purpose of a lab ventilation system is to protect

people and provide appropriate air quality

Source

CaptureDilution

& Removal

RISK

• Control Airborne Hazards

– Source Capture (ECDs)

– Dilution and Removal

– Isolation

Condition Lab Environment•Temperature–

Humidity–


Laboratories are expensive and complicated

• Average Lab Size ≈ 100,000 ft2

• Construction(USA) ≈ $45 Million to $100 Million

• Energy Cost ≈ $700,000/year ( Avg. $7 per ft2)

• Lab HVAC and Fume Hoods ≈ 30% of Construction Cost

• Fume Hood Installation ≈ $25,000 - $50,000 each

• Fume Hood Annual Cost ≈ $2,400 – $5,000 per year

Lab HVAC Energy Use

45% to 85% of the energy is consumed by Fume Hoods and the Lab HVAC Systems

As much as 50% of HVAC energy is wasted by excess airflow,

inefficient fume hoods and improper modulation of flow

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“Good science can happen in a bad building, but a

bad building can affect good science”

Poor control of environmental conditions•

Failure to meet occupant needs•

Loss of talent and poor recruitment•

Inefficient and costly to operate•

Increased risk and greater potential for liability•

Troubling Deferred Maintenance•


Why The Waste?

How Did It Happen?

• Misunderstanding of risk and risk aversion

• Labs design based on old rules of thumb

• New labs incorporating complex systems that often run at maximum capacity

• Lack of training and resources

• Failure to manage change coupled with run to failure

• Lack of standard practices to achieve and manage performance

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Old Rules

• All labs require 12 ACH

• More airflow is better and safer

• All hoods require the same face velocity

• Airflow quantity is more important than airflow distribution

• Lab exhaust must be 3000 fpm and and 10 feet above the roof

• Design, Construction and Operations are separate activities


Organizations can improve safety, reduce waste

and operate more effectively

• Attract & retain top talent

• Improve safety and reduce risk

• Minimize waste

• Maximize sustainability

• Improve resilience

• Mitigate deferred maintenance

Enhance Return on Investment

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The Roadmap to High Performance Labs

and Critical Control Environments


– President/CEO, Exposure Control Technologies, Inc.

– BSME (NCSU), MSEE – Industrial Hygiene (UNC-CH)

– Chair, AIHA/ANSI Z9 Ventilation Standards for Safety and Health

– Chair, ASHRAE TC 9.10 – Laboratory Systems

– Vice Chair, ASHRAE/ANSI 110 – Method of Testing Fume Hoods

– Board of Directors – International Institute for Sustainable Labs

– NCSU Mechanical/Aerospace Engineering Alumni Hall of Fame

– 50+ Professional Papers and Presentations

Thomas C. Smith

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Sm

art L

abs

1994

2000

2008

2012

2017


Founded to test laboratory fume hoods. Transformed to provide services and products to improve safety, reduce waste and help facilitate success.

U.S. EPA – Lab Controls Optimization Project

LCOP - Scalable and replicable program for optimizing lab safety and energy efficiency

UCI - Smart Labs™

Upgraded performance of lab buildings. Improved safety performance, occupant satisfaction and reduced energy use >50%

ANSI Lab Standards

Hazard Evaluation and Risk AssessmentLab Ventilation Management Program

DOE Smart Labs Accelerator

National partnership program based on success at EPA, UCI and elsewhere

Smart Labs™ evolved over 25 years


Smart Labs™ provides a roadmap to success

IssuesGoals

Plan

Assess

Optimize

Manage

SafeEfficient

Sustainable

• Safety• Energy Efficiency• Lab Conditions• Operating Costs• Deferred Maintenance• Reliability

Smart Lab

Qualitative Scoping Study

Quantitative Performance

Audit

Construction/Renovation

Performance Management

Plan

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The roadmap describes a systematic approach that

includes a series phases and tasks

Plan

Assess Quantitative Performance Audit

Qualitative Scoping Study

OptimizeConstruction, Renovation,

Upgrade Project

ManageLifecycle Performance

Management Plan

Phase 1A

Phase 1B

Phase 2

Phase 3


• Select & Prioritize Best Projects First

– Facility and Building Qualifying Tool

• Based on Key Performance Indicators

– Size & Space Utilization

– Energy Use & Operating Costs

– Facility Condition and Asset Value

• Building Profile Report– Classification and Categorization

– Potential for Energy Reduction

– Estimated Level of Effort, Project Costs & Potential Payback

The Qualitative Scoping Study is deployed to evaluate and prioritize building opportunities

Attribute Lab Building Profile Category

• Safety and State of the Systems

• Energy Reduction Potential

• Project LOE & Complexity

• Return on Investment (Payback)

Class A

Class B

Class C

Class D

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Roadmap to High Performance Labs

Building Design & Operating Documents

LVRA Phase 1B

Assessment

Phase 2Optimization

Phase 3Management

Airflow & Operating

Specifications

Systems Operation Tests

Energy & Operating Cost

Analysis

Engineering & Specifications

Implement Performance Improvement

Measures

Implement Performance

Management Plan

Maintenance & Functional Tests

BAS Performance Monitoring

Change Management

LVMP Team Coordination

Lab Building Inventory

Phase 1APlan

Lab Condition Status

Lab Building Condition Profile

Project Optimization

Priority For

Phase 1B

PerformanceStatus

Reports

Lab Safety Surveys

BenchmarkOperation

TAB and Commission (CX)

Building Performance

Management Plan (PMP)

for Phase 3

Quantitative Performance Audit


Ventilation drives both safety and energy use

RM 204RM 201 RM 202B RM 203RM 202A

LFH3

LFH2LFH1

AHU(s)

45

VFD%

Ex.

Fan(s)

45

VFD% OABD%VFD%

45 ∆T

Boiler

Chiller & Cooling

Tower

SupplyEnergy

Average

Min

Max

ER Coil

ER Pumps ER Coil

ECAV1 EVAV2 EVAV4 EVAV5 EVAV6EVAV3

dP°T °T°T

SVAV2 SVAV3 SVAV4

OCC

DAQSP

BAS Total Flow

DAQ

SVAV2

SP

SVAV1

DCV

Sensors

S

DCV

S

45

VFD%

∆T

Boiler

Chiller & Cooling

TowerAHU(s)

Exhaust

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• Chemical Labs

• Biology Labs (BSL 2-4)

• Radiological Labs

• Nanotechnology Labs

• Clean Rooms

• Equipment Labs

Different types of labs have different design and

operating requirements

Risk + Functional Requirements = Demand for Ventilation


The Demand for Ventilation establishes the

design and operating requirements

Minimum flow and range of modulation required to meet the functional needs of the occupants

• Safety (Risk)

– Fume Hood Flow

– Contaminant Removal (ACH)

– Isolation (Lab Pressurization)

• Comfort & Productivity

– Temperature

– Humidity

• Occupancy & Utilization

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Demand for Ventilation & Lab Utilization

Labs may be unoccupied or not in

use more than 75% of the time!74%

26%

Occupied

Max Flow

Unoccupied

Min. Flow

• Lab Time vs. Office Time

– Experiments in Lab

– Analysis in Office

• Nights and Weekends

• Holidays and Leave


Modulate flow to meet the demand for ventilation Max Supply

Min Supply

Max Exhaust

Min Exhaust

80000

90000

100000

110000

120000

130000

140000

9/1

/12

12

:00

:00

AM

PD

T

9/1

/12

6:0

0:0

0 A

M P

DT

9/1

/12

12

:00

:00

PM

PD

T

9/1

/12

5:3

0:0

0 P

M P

DT

9/1

/12

11

:00

:00

PM

PD

T

9/2

/12

5:0

0:0

0 A

M P

DT

9/2

/12

11

:00

:00

AM

PD

T

9/2

/12

5:0

0:0

0 P

M P

DT

9/2

/12

11

:00

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PM

PD

T

9/3

/12

5:0

0:0

0 A

M P

DT

9/3

/12

11

:00

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AM

PD

T

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0:0

0 P

M P

DT

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11

:00

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PM

PD

T

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0:0

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M P

DT

9/4

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11

:30

:00

AM

PD

T

9/4

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0:0

0 P

M P

DT

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:00

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PM

PD

T

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0:0

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M P

DT

9/5

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11

:00

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AM

PD

T

9/5

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4:3

0:0

0 P

M P

DT

9/5

/12

10

:30

:00

PM

PD

T

9/6

/12

4:3

0:0

0 A

M P

DT

9/6

/12

10

:30

:00

AM

PD

T

9/6

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4:0

0:0

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M P

DT

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10

:00

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PM

PD

T

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4:0

0:0

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M P

DT

9/7

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10

:00

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AM

PD

T

9/7

/12

3:3

0:0

0 P

M P

DT

9/7

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9:3

0:0

0 P

M P

DT

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3:3

0:0

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M P

DT

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9:3

0:0

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M P

DT

9/8

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3:3

0:0

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M P

DT

9/8

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9:3

0:0

0 P

M P

DT

9/9

/12

3:3

0:0

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M P

DT

9/9

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9:3

0:0

0 A

M P

DT

9/9

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3:0

0:0

0 P

M P

DT

9/9

/12

9:0

0:0

0 P

M P

DT

Flo

w -

cfm

BAS Trend of Combined Flow for AHUs 11&12,13&14,15&16,19&20 (Week September 1 - September 9, 2012)

Average Minimum Flow - cfm Maximum Flow - cfm Aggregate AHU 11-20 - Flow - cfm

Max Flow

Min Flow

AverageFlow

M T W H F

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Copyright ©2018

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Optimize Airflow Control and Energy Consumption

SupplyEnergy

Average

Min

Max

Exhaust

$/ft2 cfm/ft2 $/cfm

Maximum savings are achieved by reducing

total airflow and improving system efficiency

Energy Airflow Efficiency

Demand Operation Energy

May 2018 Copyright © 2018Proprietary & Confidential. Copyright © 2018 3 Flow, inc. All rights reserved.

Achieving proper modulation requires establishing

appropriate airflow specifications

How Much Flow is Required?

Where is the Flow Required?

When is the Flow Required?

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Where’s the risk? What flow is required?


Translating Risk to Operating Specifications

Extreme Exposure Control Device

DilutionACH

Control Measure

Primary Secondary

Glove BoxIsolator

Fume Hood

BSC

Ventilated Enclosure

Canopy

Snorkel

10 ACH

8 ACH

6 ACH

2 ACH

4 ACH

12 ACH

Airborne Hazard

Exposure Risk

Risk Level

N/ANegligible

Extreme

Low

High

Moderate

Very High

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The Lab Ventilation Risk Assessment (LVRA)

categorizes risk using control bands

• Exposure Limit (concentration)

• Quantity

• Generation Rate

• Concentration Profile

Risk Control

BandDescription

0 Negligible

1 Low

2 Moderate

3 High

4 Very High

5 Extreme

Airborne Hazard Emission Scenario


Rating of risk factors enables RCB assignment

Total

Score

Control

BandDescription

< 16 0 Negligible

16-40 1 Low

41-64 2 Moderate

65-88 3 High

89-120 4 Very High

121-160 5 Extreme

Negligible

Extreme

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RCBs differentiate labs, identify areas of concern

and help determine airflow requirements


Distribution of Labs by Risk Control BandsSuny Chemistry UCI Natural Sciences II

VA Tech - Chemistry Oak Ridge – Energy Lab

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LVRA Phase 1B

Assessment

Phase 2Optimization

Phase 3Management

Airflow & Operating

Specifications



Analysis



Measures


Management Plan



Change Management



Phase 1APlan




Priority For

Phase 1B

PerformanceStatus

Reports

Lab Safety Surveys

BenchmarkOperation




for Phase 3


• Remove or Hibernate Unnecessary Hoods

• Modify Inefficient Hoods

• Replace & Retrofit Traditional Fume Hoods

• Upgrade CAV & VAV Controls

• Optimize Temperature & Humidity Controls

• Install Demand Control Ventilation

• Reduce / Reset System Static Pressure

• Optimize Exhaust Fan and AHU Operation

• Implement Energy Recovery

Identify measures that improve performance (PIMs)

and conserve energy (ECMs)

Before Retrofit

After Retrofit

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Understanding risk has enabled development of

new technologies for safer and more efficient labs

Fume Hood upgrades:• Better containment• Lower flow

High VEFF Diffusers• Better Distribution• Lower Flow

T

100

DCV

Demand Control

Ventilation

Greater than 40% reduction

VAV Valves:• More Accurate• Better Control


Success of Smart Labs™ at UCI

Name Type*

Estimated

Avg. ACH

VAV or

CV

Was more

efficient than

code?

kWh

Savings

Therm

Savings

Total

Savings

Croul Hall P 6.6 VAV ~ 20% 41% 60% 55%

McGaugh Hall B 9.4 CV no 40% 66% 47%

Reines Hall P 11.3 CV no 70% 76% 72%

Natural Sciences II P, B 9.1 VAV ~ 20% 48% 62% 50%

Biological Sciences 3 B 9 VAV ~ 30% 45% 81% 60%

CALIT2 E 6 VAV ~ 20% 46% 78% 62%

Gillespie

Neurosciences M 6.8CV ~ 20% 58% 81% 61%

Sprague Hall M 7.2 VAV ~ 20% 58% 82% 71%

Hewitt Hall M 8.7 VAV ~ 20% 58% 77% 69%

Engineering 3 E 8 VAV ~ 30% 59% 78% 61%

Averages − 8.2 VAV ~ 20% 55% 76% 58%

Laboratory Building Before “Smart Lab” Retrofit After “Smart Lab” Retrofit

Even the most well designed and well maintained buildings can degrade over time!

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Success requires a combination of efforts

Lab Ventilation Management Plan

• Design and Mechanical Attributes

− High performance fume hoods

− Airflow Control Systems

− High efficiency mechanical systems

− Building information and control systems

• Leadership and Management

− Occupant Information and Floor Plans

− Ventilation Safety Demand Assessment

− System Diagrams and Airflow Specifications

− Lab Ventilation Management Program (LVMP)

− LVMP Coordinator/Manager




LVRA Phase 1B

Assessment

Phase 2Optimization

Phase 3Management

Airflow & Operating

Specifications



Analysis



Measures


Management Plan



Change Management



Phase 1APlan




Priority For

Phase 1B

PerformanceStatus

Reports

Lab Safety Surveys

BenchmarkOperation




for Phase 3

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Maximum safety and minimum energy use are achieved when the airflow systems dynamically modulate operation to meet the demand for ventilation.

Key Components of an Lab Ventilation Management Program (LVMP)

Risk, Demand for Ventilation & Airflow Specifications

High Performance Hoods and Airflow Control Systems

Building Information, Dashboards & Analytics

Management, Operations & Maintenance Plan

I

II

III

IV


A successful program requires leadership and

a coordinated team effort

• Stakeholder and LVMP Team (In-house and Contractors)

– Facilities and Energy Engineers

– Environmental Health and Safety

– Lab Staff Representatives

– HVAC Systems Engineer

– Laboratory Hood Specialist

– Building Controls Operator

– Mechanical Maintenance

– TAB Contractor

– Commissioning Contractor

• Program Manager/Coordinator

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The program provides the Operating Manual and

training to achieve and maintain performance

• System Line Diagrams and Drawings

• Equipment Inventories

• Lab Ventilation Risk Matrix

• Airflow Specifications

• Effective Control Sequences

• Key Performance Indicators and Metrics

• Proper Procedures and Guidelines

- Routine Tests & Maintenance Tasks

- Schedules and Management of Change

• Training for Stakeholders

Protect Return On Investment


Smart Labs™ includes training for all stakeholders

• Lab Personnel• Maintenance • Building Operators

• Program Managers & Supervisors

- Facilities Engineering

- Operations and Maintenance

- EH&S

- Lab Management LVMP Manager Coordinator

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The roadmap accelerates implementation, reduces

risk and yields more predictable results

3-6 Months 3-18 Months 6-12 Months

1 - 3 years

6-10 years

Plan Assess Optimize ManageMulti-BuildingScoping Study

Lab Building 1 Demand Assessment

Building 1Optimization

Project

Smart Labs Lifecycle Management & Maintenance Program

Building 2Phase 2

Optimization Project

Building 3Phase 2


Building 4Phase 2


Building 5Phase 2


Smart Labs™

Phase 1 - Level II Assessment Project

Smart Labs™


Smart Labs™


Smart Labs™







Project


Project


Project


Project

Prioritize and Select Building


New methods, technologies and training deliver

benefits of safer and more energy efficient labs

UniversitiesGovernment PharmaceuticalChemical

Biotechnology Industry

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Smart Labs Accelerator

Become a

Partner


Growing List of Smart Labs Accelerator Partners

▪ University of California Irvine

▪ University of Illinois (Chicago)

▪ University of Minnesota

▪ University of New Hampshire

▪ Colorado University (Boulder)

▪ Wesleyan University

▪ Emory University

▪ University of California Irvine Health

▪ Los Alamos National Laboratory

▪ Pacific Northwest National Laboratory

▪ Lawrence Berkeley National Laboratory

▪ National Renewable Energy Laboratory

▪ USDA ARS – Edward T. Schafer Argricultural Research Center

https://betterbuildingssolutioncenter.energy.gov/accelerators/smart-labs

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Interested organizations can receive access to

references, training and other services

I. Strategic Planning

II. Team Responsibilities and Training

III. Systems Theory

IV. Implementation

A. Phase 1 – Plan and Assess

B. Phase 2 – Optimize

C. Phase 3 - Manage

V. Airflow Management Program

Recently Published Guide


The right flow in the right place at

the right time!™

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Copyright ©2018

5/31/2018


Thank You!

Special Thanks and Acknowledgements:

• APPA, Leadership in Educational Facilities • The Smart Labs™ Team at the University of California Irvine (UCI)• The Better Building Alliance and the U.S. Department of Energy • The International Institute for Sustainable Labs (I2SL)


919-319-4290

[email protected]

Thomas C. SmithPresident

Hoy Bohanon Engineering, PLLC336-972-1626

[email protected]

Hoy Bohanon, PEPresident

Questions