Author: Admin Staff

Building automation is the automatic centralized control of a building’s heating, ventilation and air conditioning, lighting and other systems through a building management system or building automation system (BAS). The objectives of building automation are improved occupant comfort, efficient operation of building systems, reduction in energy consumption and operating costs, and improved life cycle of utilities.

Building automation is an example of a distributed control system – the computer networking of electronic devices designed to monitor and control the mechanical, security, fire and flood safety, lighting (especially emergency lighting), HVAC and humidity control and ventilation systems in a building.

BAS core functionality keeps building climate within a specified range, provides light to rooms based on an occupancy schedule (in the absence of overt switches to the contrary), monitors performance and device failures in all systems, and provides malfunction alarms to building maintenance staff. A BAS should reduce building energy and maintenance costs compared to a non-controlled building. Most commercial, institutional, and industrial buildings built after 2000 include a BAS. Many older buildings have been retrofitted with a new BAS, typically financed through energy and insurance savings, and other savings associated with pre-emptive maintenance and fault detection.

A building controlled by a BAS is often referred to as an intelligent building, “smart building“, or (if a residence) a “smart home“. Commercial and industrial buildings have historically relied on robust proven protocols (like BACnet) while proprietary protocols (like X-10) were used in homes. Recent IEEE standards (notably IEEE 802.15.4, IEEE 1901 and IEEE 1905.1, IEEE 802.21, IEEE 802.11ac, IEEE 802.3at) and consortia efforts like nVoy (which verifies IEEE 1905.1 compliance) or QIVICON have provided a standards-based foundation for heterogeneous networking of many devices on many physical networks for diverse purposes, and quality of service and failover guarantees appropriate to support human health and safety. Accordingly, commercial, industrial, military and other institutional users now use systems that differ from home systems mostly in scale. 

Almost all multi-story green buildings are design to accommodate a BAS for the energy, air and water conservation characteristics. Electrical device demand response is a typical function of a BAS, as is the more sophisticated ventilation and humidity monitoring required of “tight” insulated buildings. Most green buildings also use as many low-power DC devices as possible. Even a passivhausdesign intended to consume no net energy whatsoever will typically require a BAS to manage heat capture, shading and venting, and scheduling device use.

Automation system

The term building automation system, loosely used, refers to any electrical control system that is used to control a buildings heating, ventilation and air conditioning (HVAC) system. Modern BAS can also control indoor and outdoor lighting as well as security, fire alarms, and basically everything else that is electrical in the building. Old HVAC control systems, such as 24 V DC wired thermostats or pneumatic controls, are a form of automation but lack the modern systems flexibility and integration in the building. Old HVAC control systems, such as 24 V DC wired thermostats or pneumatic controls, are a form of automation but lack the modern systems flexibility and integration

BUSES AND PROTOCOLS

Most building automation networks consist of a primary and secondary bus which connect high-level controllers (generally specialized for building automation, but may be generic programmable logic controllers) with lower-level controllers, input/output devices and a user interface (also known as a human interface device). ASHRAE‘s open protocol BACnet or the open protocol LonTalk specify how most such devices interoperate. Modern systems use SNMP to track events, building on decades of history with SNMP-based protocols in the computer networking world.

Physical connectivity between devices was historically provided by dedicated optical fiber, ethernet, ARCNET, RS-232, RS-485 or a low-bandwidth special purpose wireless network. Modern systems rely on standards-based multi-protocol heterogeneous networking such as that specified in the IEEE 1905.1 standard and verified by the nVoy auditing mark. These accommodate typically only IP-based networking but can make use of any existing wiring, and also integrate powerline networking over AC circuits, power over Ethernet low-power DC circuits, high-bandwidth wireless networks such as LTE and IEEE 802.11n and IEEE 802.11ac and often integrate these using the building-specific wireless mesh open standard ZigBee).

Proprietary hardware dominates the controller market. Each company has controllers for specific applications. Some are designed with limited controls and no interoperability, such as simple packaged roof top units for HVAC. Software will typically not integrate well with packages from other vendors. Cooperation is at the Zigbee/BACnet/LonTalk level only.

Current systems provide interoperability at the application level, allowing users to mix-and-match devices from different manufacturers, and to provide integration with other compatible building control systems. These typically rely on SNMP, long used for this same purpose to integrate diverse computer networking devices into one coherent network.

TYPES OF INPUTS AND OUTPUTS

SENSORS

Analog inputs are used to read a variable measurement. Examples are temperature, humidity and pressure sensors which could be thermistor, 4–20 mA, 0–10 volt or platinum resistance thermometer (resistance temperature detector), or wireless sensors.

A digital input indicates if a device is turned on or not – however it was detected. Some examples of an inherently digital input would be a 24 V DC/AC signal, current switch, an air flow switch, or a volta-free relay contact (dry contact). Digital inputs could also be pulse type inputs counting the frequency of pulses over a given period of time. An example is a turbine flow meter transmitting rotation data as a frequency of pulses to an input.

Nonintrusive load monitoring is software relying on digital sensors and algorithms to discover appliance or other loads from electrical or magnetic characteristics of the circuit. It is however detecting the event by an analog means. These are extremely cost-effective in operation and useful not only for identification but to detect start-up transients, line or equipment faults, etc.

CONTROLS

Analog outputs control the speed or position of a device, such as a variable frequency drive, an I-P (current to pneumatics) transducer, or a valve or damper actuator. An example is a hot water valve opening up 25% to maintain a setpoint. Another example is a variable frequency drive ramping up a motor slowly to avoid a hard start.

Digital outputs are used to open and close relays and switches as well as drive a load upon command. An example would be to turn on the parking lot lights when a photocellindicates it is dark outside. Another example would be to open a valve by allowing 24VDC/AC to pass through the output powering the valve. Digital outputs could also be pulse type outputs emitting a frequency of pulses over a given period of time. An example is an energy meter calculating kWh and emitting a frequency of pulses accordingly.

 Infrastructure

CONTROLLER

Controllers are essentially small, purpose-built computers with input and output capabilities. These controllers come in a range of sizes and capabilities to control devices commonly found in buildings, and to control sub-networks of controllers.

Inputs allow a controller to read temperature, humidity, pressure, current flow, air flow, and other essential factors. The outputs allow the controller to send command and control signals to slave devices, and to other parts of the system. Inputs and outputs can be either digital or analog. Digital outputs are also sometimes called discrete depending on manufacturer.

Controllers used for building automation can be grouped in three categories: programmable logic controllers (PLCs), system/network controllers, and terminal unit controllers. However an additional device can also exist in order to integrate third-party systems (e.g. a stand-alone AC system) into a central building automation system.

Terminal unit controllers usually are suited for control of lighting and/or simpler devices such as a package rooftop unit, heat pump, VAV box, fan coil, etc. The installer typically selects one of the available pre-programmed personalities best suited to the device to be controlled, and does not have to create new control logic.

OCCUPANCY

Occupancy is one of two or more operating modes for a building automation system. Unoccupied, Morning Warmup, and Night-time Setback are other common modes.

Occupancy is usually based on time of day schedules. In Occupancy mode, the BAS aims to provides a comfortable climate and adequate lighting, often with zone-based control so that users on one side of a building have a different thermostat (or a different system, or sub system) than users on the opposite side.

A temperature sensor in the zone provides feedback to the controller, so it can deliver heating or cooling as needed.

If enabled, morning warmup (MWU) mode occurs prior to occupancy. During Morning Warmup the BAS tries to bring the building to setpoint just in time for Occupancy. The BAS often factors in outdoor conditions and historical experience to optimize MWU. This is also referred to as optimized start.

An override is a manually initiated command to the BAS. For example, many wall-mounted temperature sensors will have a push-button that forces the system into Occupancy mode for a set number of minutes. Where present, web interfaces allow users to remotely initiate an override on the BAS.

Some buildings rely on occupancy sensors to activate lighting or climate conditioning. Given the potential for long lead times before a space becomes sufficiently cool or warm, climate conditioning is not often initiated directly by an occupancy sensor.

LIGHTING

Lighting can be turned on, off, or dimmed with a building automation or lighting control system based on time of day, or on occupancy sensor, photosensors and timers. One typical example is to turn the lights in a space on for a half-hour since the last motion was sensed. A photocell placed outside a building can sense darkness, and the time of day, and modulate lights in outer offices and the parking lot.

Lighting is also a good candidate for demand response, with many control systems providing the ability to dim (or turn off) lights to take advantage of DR incentives and savings.

In newer buildings, the lighting control can be based on the field bus Digital Addressable Lighting Interface (DALI). Lamps with DALI ballasts are fully dimmable. DALI can also detect lamp and ballast failures on DALI luminaires and signals failures.

AIR HANDLERS

Most air handlers mix return and outside air so less temperature/humidity conditioning is needed. This can save money by using less chilled or heated water (not all AHUs use chilled or hot water circuits). Some external air is needed to keep the building’s air healthy. To optimize energy efficiency while maintaining healthy indoor air quality (IAQ), demand control (or controlled) ventilation (DCV) adjusts the amount of outside air based on measured levels of occupancy.

Analog or digital temperature sensors may be placed in the space or room, the return and supply air ducts, and sometimes the external air. Actuators are placed on the hot and chilled water valves, the outside air and return air dampers. The supply fan (and return if applicable) is started and stopped based on either time of day, temperatures, building pressures or a combination.

CONSTANT VOLUME AIR-HANDLING UNITS

The less efficient type of air-handler is a “constant volume air handling unit,” or CAV. The fans in CAVs do not have variable-speed controls. Instead, CAVs open and close dampersand water-supply valves to maintain temperatures in the building’s spaces. They heat or cool the spaces by opening or closing chilled or hot water valves that feed their internal heat exchangers. Generally one CAV serves several spaces.

VARIABLE VOLUME AIR-HANDLING UNITS

A more efficient unit is a “variable air volume (VAV) air-handling unit”, or VAV. VAVs supply pressurized air to VAV boxes, usually one box per room or area. A VAV air handler can change the pressure to the VAV boxes by changing the speed of a fan or blower with a variable frequency drive or (less efficiently) by moving inlet guide vanes to a fixed-speed fan. The amount of air is determined by the needs of the spaces served by the VAV boxes.

Each VAV box supply air to a small space, like an office. Each box has a damper that is opened or closed based on how much heating or cooling is required in its space. The more boxes are open, the more air is required, and a greater amount of air is supplied by the VAV air-handling unit.

Some VAV boxes also have hot water valves and an internal heat exchanger. The valves for hot and cold water are opened or closed based on the heat demand for the spaces it is supplying. These heated VAV boxes are sometimes used on the perimeter only and the interior zones are cooling only.

A minimum and maximum CFM must be set on VAV boxes to assure adequate ventilation and proper air balance.

AIR HANDLING UNIT (AHU) DISCHARGE AIR TEMPERATURE CONTROL

Air Handling units (AHU) and Roof Top units (RTU) that serve multiple zones should vary the DISCHARGE AIR TEMPERATURE SET POINT VALUE automatically in the range 55 F to 70 F. This adjustment reduces the cooling, heating, and fan energy consumption. When the outside temperature is below 70 F, for zones with very low cooling loads, raising the supply-air temperature decreases the use of reheat at the zone level

VAV HYBRID SYSTEMS

Another variation is a hybrid between VAV and CAV systems. In this system, the interior zones operate as in a VAV system. The outer zones differ in that the heating is supplied by a heating fan in a central location usually with a heating coil fed by the building boiler. The heated air is ducted to the exterior dual duct mixing boxes and dampers controlled by the zone thermostat calling for either cooled or heated air as needed.

CENTRAL PLANT

A central plant is needed to supply the air-handling units with water. It may supply a chilled water system, hot water system and a condenser water system, as well as transformersand auxiliary power unit for emergency power. If well managed, these can often help each other. For example, some plants generate electric power at periods with peak demand, using a gas turbine, and then use the turbine’s hot exhaust to heat water or power an absorptive chiller.

CHILLED WATER SYSTEM

Chilled water is often used to cool a building’s air and equipment. The chilled water system will have chiller(s) and pumps. Analog temperature sensors measure the chilled water supply and return lines. The chiller(s) are sequenced on and off to chill the chilled water supply.

A chiller is a refrigeration unit designed to produce cool (chilled) water for space cooling purposes. The chilled water is then circulated to one or more cooling coils located in air handling units, fan-coils, or induction units. Chilled water distribution is not constrained by the 100 foot separation limit that applies to DX systems, thus chilled water-based cooling systems are typically used in larger buildings. Capacity control in a chilled water system is usually achieved through modulation of water flow through the coils; thus, multiple coils may be served from a single chiller without compromising control of any individual unit. Chillers may operate on either the vapor compression principle or the absorption principle. Vapor compression chillers may utilize reciprocating, centrifugal, screw, or rotary compressor configurations. Reciprocating chillers are commonly used for capacities below 200 tons; centrifugal chillers are normally used to provide higher capacities; rotary and screw chillers are less commonly used, but are not rare. Heat rejection from a chiller may be by way of an air-cooled condenser or a cooling tower (both discussed below). Vapor compression chillers may be bundled with an air-cooled condenser to provide a packaged chiller, which would be installed outside of the building envelope. Vapor compression chillers may also be designed to be installed separate from the condensing unit; normally such a chiller would be installed in an enclosed central plant space. Absorption chillers are designed to be installed separate from the condensing unit.

CONDENSER WATER SYSTEM

Cooling towers and pumps are used to supply cool condenser water to the chillers. Because the condenser water supply to the chillers has to be constant, variable speed drives are commonly used on the cooling tower fans to control temperature. Proper cooling tower temperature assures the proper refrigerant head pressure in the chiller. The cooling tower set point used depends upon the refrigerant being used. Analog temperature sensors measure the condenser water supply and return lines.

HOT WATER SYSTEM

The hot water system supplies heat to the building’s air-handling unit or VAV box heating coils, along with the domestic hot water heating coils (Calorifier). The hot water system will have a boiler(s) and pumps. Analog temperature sensors are placed in the hot water supply and return lines. Some type of mixing valve is usually used to control the heating water loop temperature. The boiler(s) and pumps are sequenced on and off to maintain supply.

The installation and integration of variable frequency drives can lower the energy consumption of the building’s circulation pumps to about 15% of what they had been using before. A variable frequency drive functions by modulating the frequency of the electricity provided to the motor that it powers. In the US, the electrical grid uses a frequency of 60 Hertz or 60 cycles per second. Variable frequency drives are able to decrease the output and energy consumption of motors by lowering the frequency of the electricity provided to the motor, however the relationship between motor output and energy consumption is not a linear one. If the variable frequency drive provides electricity to the motor at 30 Hertz, the output of the motor will be 50% because 30 Hertz divided by 60 Hertz is 0.5 or 50%. The energy consumption of a motor running at 50% or 30 Hertz will not be 50%, but will instead be something like 18% because the relationship between motor output and energy consumption are not linear. The exact ratios of motor output or Hertz provided to the motor (which are effectively the same thing), and the actual energy consumption of the variable frequency drive / motor combination depend on the efficiency of the variable frequency drive. For example, because the variable frequency drive needs power itself to communicate with the building automation system, run its cooling fan, etc., if the motor always ran at 100% with the variable frequency drive installed the cost of operation or electricity consumption would actually go up with the new variable frequency drive installed. The amount of energy that variable frequency drives consume is nominal and is hardly worth consideration when calculating savings, however it did need to be noted that VFD’s do consume energy themselves. Because the variable frequency drives rarely ever run at 100% and spend most of their time in the 40% output range, and because now the pumps completely shut down when not needed, the variable frequency drives have reduced the energy consumption of the pumps to around 15% of what they had been using before.

 Alarms and security

All modern building automation systems have alarm capabilities. It does little good to detect a potentially hazardous or costly situation if no one who can solve the problem is notified. Notification can be through a computer (email or text message), pager, cellular phone voice call, audible alarm, or all of these. For insurance and liability purposes all systems keep logs of who was notified, when and how.

Alarms may immediately notify someone or only notify when alarms build to some threshold of seriousness or urgency. At sites with several buildings, momentary power failures can cause hundreds or thousands of alarms from equipment that has shut down – these should be suppressed and recognized as symptoms of a larger failure. Some sites are programmed so that critical alarms are automatically re-sent at varying intervals. For example, a repeating critical alarm (of an uninterruptible power supply in ‘bypass’) might resound at 10 minutes, 30 minutes, and every 2 to 4 hours thereafter until the alarms are resolved.

• Common temperature alarms are: space, supply air, chilled water supply, hot water supply.
• Pressure, humidity, biological and chemical sensors can determine if ventilation systems have failed mechanically or become infected with contaminants that affect human health.
• Differential pressure switches can be placed on a filter to determine if it is dirty or otherwise not performing.
• Status alarms are common. If a mechanical device like a pump is requested to start, and the status input indicates it is off, this can indicate a mechanical failure. Or, worse, an electrical fault that could represent a fire or shock hazard.
• Some valve actuators have end switches to indicate if the valve has opened or not.
• Carbon monoxideand carbon dioxide sensors can tell if concentration of these in the air are too high, either due to fire or ventilation problems in garages or near roads.
• Refrigerantsensors can be used to indicate a possible refrigerant leak.
• Current sensors can be used to detect low current conditions caused by slipping fan belts, clogging strainers at pumps, or other problems.

Security systems can be interlocked to a building automation system. If occupancy sensors are present, they can also be used as burglar alarms. Because security systems are often deliberately sabotaged, at least some detectors or cameras should have battery backup and wireless connectivity and the ability to trigger alarms when disconnected. Modern systems typically use power-over-Ethernet (which can operate a pan-tilt-zoom camera and other devices up to 30–90 watts) which is capable of charging such batteries and keeps wireless networks free for genuinely wireless applications, such as backup communication in outage.

Fire alarm panels and their related smoke alarm systems are usually hard-wired to override building automation. For example: if the smoke alarm is activated, all the outside air dampers close to prevent air coming into the building, and an exhaust system can isolate the blaze. Similarly, electrical fault detection systems can turn entire circuits off, regardless of the number of alarms this triggers or persons this distresses. Fossil fuel combustion devices also tend to have their own over-rides, such as natural gas feed lines that turn off when slow pressure drops are detected (indicating a leak), or when excess methane is detected in the building’s air supply.

Good BAS are aware of these overrides and recognize complex failure conditions. They do not send excessive alerts, nor do they waste precious backup power on trying to turn back on devices that these safety over-rides have turned off. A poor BAS, almost by definition, sends out one alarm for every alert, and does not recognize any manual, fire or electric or fuel safety override. Accordingly, good BAS are often built on safety and fire systems.

INFORMATION SECURITY

With the growing spectrum of capabilities and their connection with the Internet, building automation systems were repeatedly reported to be vulnerable, allowing hackers and cybercriminals to attack their components. Buildings can be exploited by hackers to measure or change their environment: sensors allow surveillance (e.g. monitoring movements of employees or habits of inhabitants) while actuators allow to perform actions in buildings (e.g. opening doors or windows for intruders). Several vendors and committees started to improve the security features in their products and standards, including KNX, ZigBee and BACnet (see recent standards or standard drafts). However, researchers report several open problems in building automation security.

Source : https://en.wikipedia.org/wiki/Building_automation

An air handler, or air handling unit (often abbreviated to AHU), is a device used to regulate and circulate air as part of a heating, ventilating, and air-conditioning (HVAC) system. An air handler is usually a large metal box containing a blower, heating or cooling elements, filter racks or chambers, sound attenuators, and dampers. Air handlers usually connect to a ductwork ventilation systemthat distributes the conditioned air through the building and returns it to the AHU. Sometimes AHUs discharge (supply) and admit (return) air directly to and from the space served without ductwork.

Small air handlers, for local use, are called terminal units, and may only include an air filter, coil, and blower; these simple terminal units are called blower coils or fan coil units. A larger air handler that conditions 100% outside air, and no recirculated air, is known as a makeup air unit (MAU). An air handler designed for outdoor use, typically on roofs, is known as a packaged unit (PU) or rooftop unit (RTU).

Construction

The air handler is normally constructed around a framing system with metal infill panels as required to suit the configuration of the components. In its simplest form the frame may be made from metal channels or sections, with single skin metal infill panels. The metalwork is normally galvanized for long term protection. For outdoor units some form of weatherproof lid and additional sealing around joints is provided.

Larger air handlers will be manufactured from a square section steel framing system with double skinned and insulated infill panels. Such constructions reduce heat loss or heat gain from the air handler, as well as providing acoustic attenuation. Larger air handlers may be several meters long and are manufactured in a sectional manner and therefore, for strength and rigidity, steel section base rails are provided under the unit.

Where supply and extract air is required in equal proportions for a balanced ventilation system, it is common for the supply and extract air handlers to be joined together, either in a side-by-side or a stacked configuration.

Components

The major types of components are described here in approximate order, from the return duct (input to the AHU), through the unit, to the supply duct (AHU output)

Filters

Air filtration is almost always present in order to provide clean dust-free air to the building occupants. It may be via simple low-MERV pleated media, HEPA, electrostatic, or a combination of techniques. Gas-phase and ultraviolet air treatments may be employed as well.

Filtration is typically placed first in the AHU in order to keep all the downstream components clean. Depending upon the grade of filtration required, typically filters will be arranged in two (or more) successive banks with a coarse-grade panel filter provided in front of a fine-grade bag filter, or other “final” filtration medium. The panel filter is cheaper to replace and maintain, and thus protects the more expensive bag filters.

The life of a filter may be assessed by monitoring the pressure drop through the filter medium at design air volume flow rate. This may be done by means of a visual display using a pressure gauge, or by a pressure switch linked to an alarm point on the building control system. Failure to replace a filter may eventually lead to its collapse, as the forces exerted upon it by the fan overcome its inherent strength, resulting in collapse and thus contamination of the air handler and downstream ductwork.

Heating and/or cooling elements

Air handlers may need to provide heating, cooling, or both to change the supply air temperature, and humidity level depending on the location and the application. Such conditioning is provided by heat exchanger coil(s) within the air handling unit air stream, such coils may be direct or indirect in relation to the medium providing the heating or cooling effect.

Direct heat exchangers include those for gas-fired fuel-burning heaters or a refrigeration evaporator, placed directly in the air stream. Electric resistance heaters and heat pumps can be used as well. Evaporative cooling is possible in dry climates.

Indirect coils use hot water or steam for heating, and chilled water for cooling (prime energy for heating and cooling is provided by central plant elsewhere in the building). Coils are typically manufactured from copper for the tubes, with copper or aluminium fins to aid heat transfer. Cooling coils will also employ eliminator plates to remove and drain condensate. The hot water or steam is provided by a central boiler, and the chilled water is provided by a central chiller. Downstream temperature sensors are typically used to monitor and control “off coil” temperatures, in conjunction with an appropriate motorized control valve prior to the coil.

If dehumidification is required, then the cooling coil is employed to over-cool to that the dew point is reached and condensation occurs. A heater coil placed after the cooling coil re-heats the air (therefore known as a re-heat coil) to the desired supply temperature. This process has the effect of reducing the relative humidity level of the supply air.

In colder climates, where winter temperatures regularly drop below freezing, then frost coils or pre-heat coils are often employed as a first stage of air treatment to ensure that downstream filters or chilled water coils are protected against freezing. The control of the frost coil is such that if a certain off-coil air temperature is not reached then the entire air handler is shut down for protection.

Humidifier

Humidification is often necessary in colder climates where continuous heating will make the air drier, resulting in uncomfortable air quality and increased static electricity. Various types of humidification may be used:

• Evaporative: dry air blown over a reservoir will evaporate some of the water. The rate of evaporation can be increased by spraying the water onto baffles in the air stream.
• Vaporizer: steam or vapor from a boiler is blown directly into the air stream.
• Spray mist: water is diffused either by a nozzle or other mechanical means into fine droplets and carried by the air.
• Ultrasonic: A tray of fresh water in the airstream is excited by an ultrasonic device forming a fog or water mist.
• Wetted medium: A fine fibrous medium in the airstream is kept moist with fresh water from a header pipe with a series of small outlets. As the air passes through the medium it entrains the water in fine droplets. This type of humidifier can quickly clog if the primary air filtration is not maintained in good order.

Mixing chamber

In order to maintain indoor air quality, air handlers commonly have provisions to allow the introduction of outside air into, and the exhausting of air from the building. In temperate climates, mixing the right amount of cooler outside air with warmer return air can be used to approach the desired supply air temperature. A mixing chamber is therefore used which has dampers controlling the ratio between the return, outside, and exhaust air.

Blower/Fan

Air handlers typically employ a large squirrel cage blower driven by an AC induction electric motor to move the air. The blower may operate at a single speed, offer a variety of set speeds, or be driven by a variable-frequency drive to allow a wide range of air flow rates. Flow rate may also be controlled by inlet vanes or outlet dampers on the fan. Some residential air handlers in USA (central “furnaces” or “air conditioners”) use a brushless DC electric motor that has variable speed capabilities. Air handlers in Europe and Australia and New Zealand now commonly use backward curve fans without scroll or “plug fans”. These are driven using high efficiency EC (electronically commutated) motors with built in speed control.

Multiple blowers may be present in large commercial air handling units, typically placed at the end of the AHU and the beginning of the supply ductwork (therefore also called “supply fans”). They are often augmented by fans in the return air duct (“return fans”) pushing the air into the AHU.

Balancing

Un-balanced fans wobble and vibrate. For home AC fans, this can be a major problem: air circulation is greatly reduced at the vents (as wobble is lost energy), efficiency is compromised, and noise is increased. Another major problem in fans that are not balanced is longevity of the bearings (attached to the fan and shaft) is compromised. This can cause failure to occur long before the bearings life expectancy.

Weights can be strategically placed to correct for a smooth spin (for a ceiling fan, trial and error placement typically resolves the problem). Home / central AC fans or other big fans are typically taken to shops, which have special balancers for more complicated balancing (trial and error can cause damage before the correct points are found). The fan motor itself does not typically vibrate.

Heat Recover Device

A heat recovery device heat exchanger may be fitted to the air handler between supply and extract airstreams for energy savings and increasing capacity. These types more commonly include for:

• Recuperator, or Plate Heat exchanger: A sandwich of plastic or metal plates with interlaced air paths. Heat is transferred between airstreams from one side of the plate to the other. The plates are typically spaced at 4 to 6mm apart. Heat recovery efficiency up to 70%.
• Thermal Wheel, or Rotary heat exchanger: A slowly rotating matrix of finely corrugated metal, operating in both opposing airstreams. When the air handling unit is in heating mode, heat is absorbed as air passes through the matrix in the exhaust airstream, during one half rotation, and released during the second half rotation into the supply airstream in a continuous process. When the air handling unit is in cooling mode, heat is released as air passes through the matrix in the exhaust airstream, during one half rotation, and absorbed during the second half rotation into the supply airstream. Heat recovery efficiency up to 85%. Wheels are also available with a hydroscopic coatingto provide latent heat transfer and also the drying or humidification of airstreams.
• Run around coil: Two air to liquid heat exchanger coils, in opposing airstreams, piped together with a circulating pump and using water or a brine as the heat transfer medium. This device, although not very efficient, allows heat recovery between remote and sometimes multiple supply and exhaust airstreams. Heat recovery efficiency up to 50%.
• Heat Pipe: Operating in both opposing air paths, using a confined refrigerantas a heat transfer medium. The heat pipe uses multiple sealed pipes mounted in a coil configuration with fins to increase heat transfer. Heat is absorbed on one side of the pipe, by evaporation of the refrigerant, and released at the other side, by condensation of the refrigerant. Condensed refrigerant flows by gravity to the first side of the pipe to repeat the process. Heat recovery efficiency up to 65%.

Controls

Controls are necessary to regulate every aspect of an air handler, such as: flow rate of air, supply air temperature, mixed air temperature, humidity, air quality. They may be as simple as an off/on thermostat or as complex as a building automation system using BACnet or LonWorks, for example.

Common control components include temperature sensors, humidity sensors, sail switches, actuators, motors, and controllers.

Vibration Isolators

The blowers in an air handler can create substantial vibration and the large area of the duct system would transmit this noise and vibration to the occupants of the building. To avoid this, vibration isolators (flexible sections) are normally inserted into the duct immediately before and after the air handler and often also between the fan compartment and the rest of the AHU. The rubberized canvas-like material of these sections allows the air handler components to vibrate without transmitting this motion to the attached ducts.

The fan compartment can be further isolated by placing it on a spring suspension, which will mitigate the transfer of vibration through the floor.

Source : wikipedia

Preventive maintenance (PM)  is “a routine for periodically inspecting” with the goal of “noticing small problems and fixing them before major ones develop.” Ideally, “nothing breaks down.

The main goal behind PM is for the equipment to make it from one planned service to the next planned service without any failures caused by fatigue, neglect, or normal wear (preventable items), which Planned Maintenance and Condition Based Maintenance help to achieve by replacing worn components before they actually fail. Maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication, minor adjustments, and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause system failure.

The New York Times gave an example of “machinery that is not lubricated on schedule” that functions “until a bearing burns out.” Preventive maintenance contracts are generally a fixed cost, whereas improper maintenance introduces a variable cost: replacement of major equipment.

Preventive maintenance or preventative maintenance (PM) has the following meanings:

• The care and servicing by personnel for the purpose of maintaining equipment in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects.
• The work carried out on equipment in order to avoid its breakdown or malfunction. It is a regular and routine action taken on equipment in order to prevent its breakdown.
• Maintenance, including tests, measurements, adjustments, parts replacement, and cleaning, performed specifically to prevent faults from occurring.

Other terms and abbreviations related to PM are:

• scheduled maintenance^]
• planned maintenance, which may include scheduled downtime for equipment replacement
• planned preventive maintenance (PPM) is another name for PM
• breakdown maintenance: fixing things only when they break. This is also known as “a reactive maintenance strategy and may involve “consequential damage.

Planned maintenance

Planned preventive maintenance (PPM), more commonly referred to as simply planned maintenance (PM) or scheduled maintenance, is any variety of scheduled maintenance to an object or item of equipment. Specifically, planned maintenance is a scheduled service visit carried out by a competent and suitable agent, to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime.

The key factor as to when and why this work is being done is timing, and involves a service, resource or facility being unavailable By contrast, condition-based maintenance is not directly based on equipment age.

Planned maintenance is preplanned, and can be date-based, based on equipment running hours, or on distance travelled.

Parts that have scheduled maintenance at fixed intervals, usually due to wearout or a fixed shelf life, are sometimes known as time-change interval, or TCI items.

Predictive replacemente

Predictive replacement is the replacement of an item that is still functioning properly. Usually it’s a tax-benefit based replacement policy whereby expensive equipment or batches of individually inexpensive supply items are removed and donated on a predicted/fixed shelf life schedule. These items are given to tax-exempt institutions.

Condition-based maintenance

Condition-based maintenance (CBM), shortly described, is maintenance when need arises. Albeit chronologically much older, It is considered one section or practice inside the broader and newer predictive maintenance field, where new AI technologies and connectivity abilities are put to action and where the acronym CBM is more often used to describe ‘condition Based Monitoring’ rather than the maintenance itself. CBM maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating.

This concept is applicable to mission-critical systems that incorporate active redundancy and fault reporting. It is also applicable to non-mission critical systems that lack redundancy and fault reporting.

Condition-based maintenance was introduced to try to maintain the correct equipment at the right time. CBM is based on using real-time data to prioritize and optimize maintenance resources. Observing the state of the system is known as condition monitoring. Such a system will determine the equipment’s health, and act only when maintenance is actually necessary. Developments in recent years have allowed extensive instrumentation of equipment, and together with better tools for analyzing condition data, the maintenance personnel of today is more than ever able to decide what is the right time to perform maintenance on some piece of equipment. Ideally, condition-based maintenance will allow the maintenance personnel to do only the right things, minimizing spare parts cost, system downtime and time spent on maintenance.

Challenges

Despite its usefulness, there are several challenges to the use of CBM. First and most important of all, the initial cost of CBM can be high. It requires improved instrumentation of the equipment. Often the cost of sufficient instruments can be quite large, especially on equipment that is already installed. Wireless systems have reduced the initial cost. Therefore, it is important for the installer to decide the importance of the investment before adding CBM to all equipment. A result of this cost is that the first generation of CBM in the oil and gas industry has only focused on vibration in heavy rotating equipment.

Secondly, introducing CBM will invoke a major change in how maintenance is performed, and potentially to the whole maintenance organization in a company. Organizational changes are in general difficult.

Also, the technical side of it is not always as simple. Even if some types of equipment can easily be observed by measuring simple values as vibration (displacement or acceleration), temperature or pressure, it is not trivial to turn this measured data into actionable knowledge about the health of the equipment.

Value potential

As systems get more costly, and instrumentation and information systems tend to become cheaper and more reliable, CBM becomes an important tool for running a plant or factory in an optimal manner. Better operations will lead to lower production cost and lower use of resources. And lower use of resources may be one of the most important differentiators in a future where environmental issues become more important by the day.

A more down to earth scenario where value can be created is by monitoring the health of your car motor. Rather than changing parts at predefined intervals, the car itself can tell you when something needs to be changed based on cheap and simple instrumentation.

It is Department of Defense policy that condition-based maintenance (CBM) be “implemented to improve maintenance agility and responsiveness, increase operational availability, and reduce life cycle total ownership costs”

Advantages and disadvantages

CBM has some advantages over planned maintenance:

• Improved system reliability
• Decreased maintenance costs
• Decreased number of maintenance operations causes a reduction of human errorinfluences

Its disadvantages are:

• High installation costs, for minor equipment items often more than the value of the equipment
• Unpredictable maintenance periods cause costs to be divided unequally
• Increased number of parts (the CBM installation itself) that need maintenance and checking

Today, due to its costs, CBM is not used for less important parts of machinery despite obvious advantages. However it can be found everywhere where increased reliability and safety is required, and in future will be applied even more widely.

Corrective

Corrective maintenance is a type of maintenance used for equipment after equipment break down or malfunction is often most expensive – not only can worn equipment damage other parts and cause multiple damage, but consequential repair and replacement costs and loss of revenues due to down time during overhaul can be significant. Rebuilding and resurfacing of equipment and infrastructure damaged by erosion and corrosion as part of corrective or preventive maintenance programmes involves conventional processes such as welding and metal flame spraying, as well as engineered solutions with thermoset polymeric materials.

Predictive

More recently, advances in sensing and computing technology have given rise to predictive maintenance (PdM). This maintenance strategy uses sensors to monitor key parameters within a machine or system, and uses this data in conjunction with analysed historical trends to continuously evaluate the system health and predict a breakdown before it happens.This strategy allows maintenance to be performed more efficiently, since more up-to-date data is obtained about how close the product is to failure

Source : https://en.wikipedia.org/