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DOE OSTI2020

Provider and User Perspectives on Automated Fault Detection and Diagnostic Products for Packaged Rooftop Units

The goal of this project was to understand, based on the primary reporting of AFDD providers and building owners, 1) the features currently available for RTU AFDD in the market today, 2) how RTU AFDD is used by building owners and managers, 3) how well RTU AFDD meets their needs, and 4) what barriers stand in the way of its broad industry adoption. To achieve this goal, 13 AFDD providers were asked about their products and seven building owners were questioned about their practical experience related to the automated detection, diagnosis, and communication of RTU faults.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Unified architecture for data-driven metadata tagging of building automation systems

This article presents a Unified Architecture (UA) for automated point tagging of Building Automation System (BAS) data, based on a combination of data-driven approaches. Advanced energy analytics applications—including fault detection and diagnostics and supervisory control—have emerged as a significant opportunity for improving the performance of our built environment. Effective application of these analytics depends on harnessing structured data from the various building control and monitoring systems, but typical BAS implementations do not employ any standardized metadata schema. While standards such as Project Haystack and Brick Schema have been developed to address this issue, the process of structuring the data, i.e., tagging the points to apply a standard metadata schema, has, to date, been a manual process. This process is typically costly, labor-intensive, and error-prone. In this work we address this gap by proposing a UA that automates the process of point tagging by leveraging the data accessible through connection to the BAS, including time-series data and the raw point names. The UA intertwines supervised classification and unsupervised clustering techniques from machine learning and leverages both their deterministic and probabilistic outputs to inform the point tagging process. Furthermore, we extend the UA to embed additional input and output data-processing modules that are designed to address the challenges associated with the real-time deployment of this automation solution. We test the UA on two datasets for real-life buildings: (i) commercial retail buildings and (ii) office buildings from the National Renewable Energy Laboratory (NREL) campus. We report the proposed methodology correctly applied 85–90% and 70–75% of the tags in each of these test scenarios, respectively for two significantly different building types used for testing UA's fully-functional prototype. The proposed UA, therefore, offers promising approach for automatically tagging BAS data as it reaches close to 90% accuracy. Further building upon this framework to algorithmically identify the equipment type and their relationships is an apt future research direction to pursue.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Design, Development and Testing Plan for Energy Efficiency Algorithms Related to Building-Integrated Cooling, Heating, and Power Systems

Building-integrated cooling, heating and power (CHP) systems are more efficient than conventional systems at providing local power and thermal energy, and favorable fuel prices are bound to spur their increased adoption. It is estimated that the total CHP technical potential in the commercial building sector is approximately 76 GW, but only a small fraction of it is actually deployed. Advanced control and monitoring systems that realize the full potential of these CHP systems can transform this capacity into an asset for both the owner and the grid and also accelerate the adoption of these systems in the building sector. However, to realize the full benefit of the CHP systems, we must ensure persistence of energy efficient operations. It has been demonstrated by several studies that as much as 30% of building energy use is wasted. Much of the waste results from the inability to anticipate load variations (design day vs. non-design day operations; diurnal variation of loads), identify improper operation, and efficiently operate, control and maintain building systems. Moreover, many buildings, even those with adequate control infrastructure, lack knowledgeable staff to operate and maintain energy systems. Operators of buildings with CHP systems will constantly need to make tradeoffs (economic dispatch) between onsite power generation and purchasing power, between onsite heat production from distributed generation versus heating/cooling from conventional systems, and different passive and active load management measures. Much of the inefficiency in the current building operations can be eliminated by use of automated performance monitoring (PM), real-time commissioning verification (CxV) and automated fault detection and diagnostic (AFDD) tools. Automation can help system operators make intelligent decisions. Remote and continuous monitoring of system conditions and performance will enable better management and integration of CHP with existing building systems. Continuous PM, real-time CxV and AFDD could alleviate burdens for operations staff, enhance operations and maintenance (O&M), and improve reliability of building and CHP systems. To address the O&M challenges and to provide a means to maximize the rate-of-return of building-integrated CHP systems, the Building Technologies Office (BTO) within the U.S. Department of Energy’s (DOE’s) Office of Energy Efficiency and Renewable Energy (EERE) initiated a project to design, develop, and field test a VOLTTRON™-based supervisory controller and associated open-source algorithms. These algorithms will ensure real-time optimal operation of a building-integrated CHP system, support electric grid reliability, and lead to achieving the goal of a clean, efficient, reliable and affordable next-generation integrated energy systems. This report lists the components for which PM, real-time CxV and AFDD algorithms will be developed, how the algorithms will be tested, and metrics that will be used to validate the algorithms and easy of deployment. Deployment of these algorithms in the field will result in savings reduction in energy consumption of between 10% and 20%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Implementation Plan for Combined Heat and Power Systems VOLTTRON Controller: Performance Monitoring and Real-Time Commissioning Algorithm Verification

Building-integrated cooling, heating, and power (CHP) systems are more efficient than conventional systems at providing local power and thermal energy, and favorable fuel prices are bound to spur their increased adoption. However, to realize the full benefit of the CHP systems, we must ensure persistence of energy efficient operations. Much of the inefficiency in the current building operations can be eliminated by use of automated performance monitoring (PM), real-time commissioning verification (CxV) and automated fault detection and diagnostic (AFDD) tools. Automation can help system operators make intelligent decisions. Remote and continuous monitoring of system conditions and performance will enable better management and integration of CHP with existing building systems. Continuous PM, real-time CxV, and AFDD could alleviate burdens for operations staff, enhance operations and maintenance (O&M), and improve reliability of building and CHP systems. To address the O&M challenges and to provide a means to maximize the rate-of-return of building-integrated CHP systems, the Building Technologies Office (BTO) within the U.S. Department of Energy’s (DOE’s) Office of Energy Efficiency and Renewable Energy (EERE) initiated a project to design, develop, and field test a VOLTTRON™-based supervisory controller and associated open-source algorithms. These algorithms will ensure real-time optimal operation of a building-integrated CHP system, support electric grid reliability, and lead to achieving the goal of clean, efficient, reliable, and affordable next-generation integrated energy system. Previous report listed the components for which PM, real-time CxV, and AFDD algorithms will be developed, how the algorithms will be tested, and the metrics that will be used to validate the algorithms and their ease of deployment. Deployment of these algorithms in the field will result in a reduction in energy consumption of between 10% and 20% (for both CHP and conventional building systems). This report builds upon the previous report by detailing the process by which PNNL will implement performance monitoring and real-time commissioning algorithms for CHP systems in conjunction with the use of the VOLTTRON CHP economic dispatch agent in host facilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Virtual Metering for Monitoring Building Energy Consumption

The United States Department of Energy (DOE) has standard metering requirements of commercial buildings for optimizing energy performance. The guiding principles are to continuously track and optimize energy performance and install building-level meters for electricity, natural gas, and steam. Some buildings at Los Alamos National Laboratory (LANL) have physical submeters monitoring their energy consumption, but these meters have proven to be unreliable. And, in most cases, replacing them has proven to be a slow process. Installing new submeters also requires a temporary lockout of the circuit on which they are being installed. Many buildings at LANL contain laboratories with ongoing experiments or data centers, which makes an equipment power outage nearly impossible to plan. This inability to plan power outages results in long-term submeter failures. Although most submeters are eventually replaced, failures lead to missing consumption data for some unpredictable, extended time. A building automation system (BAS) is a system that provides control and monitoring on a building to maintain the operational performance of the building and occupancy comfort. Many buildings at LANL currently have a BAS, and all new renovations and installs will include installing a BAS if one does not already exist. The intended purpose for a BAS is primarily to monitor the health and efficiency of a building; however, it is also possible to calculate equipment power and energy consumption using BAS information. This project aims to use virtual meters to monitor building energy consumption as a cost-effective and minimally labor-intensive alternative to installing physical submeters. The fault detection and diagnostics tool, SkySpark, provides a centralized database for all the data from the various BAS that are active at LANL. This data includes the information that is needed to create virtual meters for heating, ventilating, and air conditioning (HVAC) systems in most buildings, including heating and cooling loads. 9 This report begins with a detailed summary of the project, including the reasoning, procedure, and results. The specific processes of creating the various virtual meters are then identified. Then the limitations are discussed. And, lastly, the results and future potential are presented.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Empirical Modeling of Direct Expansion (DX) Cooling System for Multiple Research Use Cases

This study provides a general procedure to generate a direct expansion (DX) cooling coil system for a roof top unit (RTU), which is a typical heating ventilation and air-conditioning (HVAC) system for commercial buildings in the United States. Experimental data from a full-scale unoccupied 2-story commercial building is used for the HVAC modeling. The regression for identifying the model coefficients was carried out with multiple stages, and the results were validated with measured data. The model’s applicability was evaluated with multiple case studies, including a building energy simulation (BES) program validation, model-based predictive control (MPC), and fault diagnostics and detection (FDD).

42 ENGINEERING↗

DOE OSTI2022

Towards a Stronger Foundation: Digitizing Commercial Buildings with Brick to Enable Portable Advanced Applications

Most large commercial buildings have digital controls for their heating, ventilation, and air-conditioning (HVAC) and lighting systems with the potential to implement advanced control strategies and data analytics. However, advanced control strategies and data analytics are rarely deployed at scale due to non-standard naming conventions and heterogenous building configurations. Semantic metadata standards, like Brick, show promise to proliferate these applications across many buildings, but they have not been widely adopted by industry due to barriers such as perceived risk and unfamiliarity with the technology. This paper describes the workflow we established and evaluated while using it to develop over ten Brick models of existing buildings. Through this process, we observed that digitizing existing commercial buildings is a cost and labor-intensive effort in which understanding the buildings’ data streams is the major bottleneck. Yet, we conclude this investment is worthwhile since various use case applications such as fault detection and diagnostics, thermal comfort analysis, and HVAC control optimization can utilize the same Brick model. The paper also explores the challenges and lessons learned we encountered while creating these data models, such as: 1) difficulties in finding metadata descriptions and relationships for existing buildings; 2) handling missing concepts in the schema needed to model a building; 3) lack of guidance on how to structure the data model or how much detail to include; 4) unfamiliarity with technologies, which makes the learning curve steep for applications developers. Finally, we also describe future directions for semantic metadata research and development to make such transformative technologies more accessible to practitioners.

Roa, Carlos Duarte↗

DOE OSTI2025

Optimizing Hydronic Heating for Comfort and Performance in Multifamily Housing

Inefficient control settings in multifamily boilers often lead to substantial energy and cost penalties. To address this, a Fault Detection and Diagnostic (FDD) tool was developed to automate data analysis and identify operational faults such as suboptimal outdoor temperature sensor placement, misconfigured outdoor air reset (OAR) curves, excess boiler cycling, and domestic hot water (DHW) setpoint errors. By comparing pre- and post-implementation periods and applying engineering models, the tool quantifies energy savings and reduces manual analysis time by over 90%. Testing on over 100 monitored sites and a targeted subset of 12 buildings showed an average 11% energy savings from remote optimization; further validation across 19 OAR curve changes confirmed the tool’s accuracy, predicting actual savings within ±5% for most cases. Simple payback can be under three years for many multifamily buildings, though rising hardware, labor, and fuel costs create uncertainties, and decarbonization goals increasingly shift focus to electrification. The FDD tool remains invaluable for optimizing existing boilers, enhancing future electrification measures, and adapting to new technologies by refining building load estimates. In doing so, it supports both near-term efficiency and long-term transitions to low-carbon alternatives, ensuring buildings achieve substantial cost and energy benefits throughout their system lifecycles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

What's in a Name? Developing a Standardized Taxonomy for HVAC System Faults

Faults occurring in heating, ventilation and air-conditioning (HVAC) systems have significantly negative impacts on building energy consumption, occupant comfort, and indoor air quality. In the past thirty years, extensive research has been conducted on fault detection and diagnostics (FDD) methods, and there are now dozens of commercially available FDD software tools. Growing adoption of FDD tools has the potential to generate a massive and useful data set on fault characteristics. However, the lack of a unifying taxonomy is a significant barrier to efficient analysis and evaluation of FDD outputs. Therefore, there is a strong need to develop a robust taxonomy which can better represent and interpret FDD output data. This paper documents the development of a unifying taxonomy for HVAC system faults in commercial buildings, with initial focus on air handling units, variable air volume terminal units, and roof top unit systems. The developed fault taxonomy employs both a physical hierarchy of HVAC equipment and a cause-effect relationship model as tools to better understand and support root cause analysis for HVAC faults. A variable air volume terminal unit is used as an example to demonstrate the application of the developed fault taxonomy. The taxonomy has short-term application in a major U.S. study on fault prevalence, and promises longer term benefits to FDD software developers and building operators by creating a foundation for improved approaches to identifying and resolving HVAC faults.

Chen, Yimin↗

DOE OSTI2026

Field-based AFDD for refrigerant undercharge in residential HVAC systems: enhancing reliability through false alarm mitigation

This study evaluated rule-based and machine learning (ML) based automated fault detection and diagnostics (AFDD) algorithms for detecting refrigerant undercharge faults in residential heating, ventilation, and air conditioning (HVAC) systems, using actual building data and a minimal set of features. The ML-based algorithms included Decision Tree (DT) and K-Nearest Neighbors (KNN). Both the rule-based and ML-based algorithms demonstrated the capability to detect refrigerant undercharge faults of -30% or more. Both types of algorithms exhibited false alarms before the implementation of a false alarm mitigation algorithm, which motivated the development of such a mitigation strategy. After applying the mitigation, false alarms were substantially reduced, with the rule-based algorithm decreasing to 0.6% and the ML-based algorithms reaching 0%, while maintaining strong detection performance. Although the rule-based algorithm initially showed lower performance compared to the ML-based algorithms, its detection accuracy improved after mitigation to a level comparable to the ML-based algorithms. These results confirm that combining false alarm mitigation with both rule-based and ML-based AFDD algorithms significantly enhances practical reliability while preserving robust fault detection capabilities. Furthermore, the findings demonstrate the potential for field deployment of these algorithms in residential HVAC systems and highlight the importance of minimizing false alarms.

False Alarm↗

DOE OSTI2020

Curation of Ground-Truth Validated Benchmarking Datasets for Fault Detection & Diagnostics Tools

Fault detection and diagnostics (FDD) analytical tools for heating, ventilation and air conditioning (HVAC) systems represent one of the most active areas of smart building technology development. A diversity of techniques is used for FDD analytics, spanning physical models, black box, and rule-based approaches, and researchers continuously strive to develop improved algorithms. With FDD algorithm numbers now in the hundreds, there is a need for performance evaluation of these algorithms in order to assess improvements, improve costeffectiveness, and to prioritize investment in the further development of these technologies. A persistent challenge of FDD advance has been the lack of common datasets to benchmark the performance accuracy of FDD algorithms. This paper summarizes the successful curation of HVAC operational data, paired with validated ground-truth information regarding the presence and absence of faults. The current dataset, consisting of both simulation and experimental data, will evolve to include a larger set of HVAC systems with the objective of creating the largest publicly available dataset to be used by FDD developers, users, and researchers to compare and contrast performance accuracy across FDD algorithms, helping to drive improvements that will spur greater market adoption of FDD tools. Furthermore, in order to avoid previously observed issues with contributed datasets and ensure high quality and consistency of future submissions, the development of data validation and ground-truth assessment protocol is detailed in this study.

Casillas, Armando↗

DOE OSTI2024

Innovating the next generation of commercial smart building software

Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.

Casillas, Armando↗

NASA NTRS2010

Ares I-X Ground Diagnostic Prototype

The automation of pre-launch diagnostics for launch vehicles offers three potential benefits: improving safety, reducing cost, and reducing launch delays. The Ares I-X Ground Diagnostic Prototype demonstrated anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage Thrust Vector Control and for the associated ground hydraulics while the vehicle was in the Vehicle Assembly Building at Kennedy Space Center (KSC) and while it was on the launch pad. The prototype combines three existing tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool from Qualtech Systems Inc. for fault isolation and diagnostics. The second tool, SHINE (Spacecraft Health Inference Engine), is a rule-based expert system that was developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification, and used the outputs of SHINE as inputs to TEAMS. The third tool, IMS (Inductive Monitoring System), is an anomaly detection tool that was developed at NASA Ames Research Center. The three tools were integrated and deployed to KSC, where they were interfaced with live data. This paper describes how the prototype performed during the period of time before the launch, including accuracy and computer resource usage. The paper concludes with some of the lessons that we learned from the experience of developing and deploying the prototype.

Schwabacher, Mark A.↗

DOE OSTI2021

Energy Management Information System Powers NREL's Intelligent Campus

NREL's Intelligent Campus program leverages its own laboratory buildings as research instruments to study renewable energy, energy efficiency, and energy storage, integration, and analysis with real, quantitative measurements. At the heart of NREL's Intelligent Campus program is its Energy Management Information System (EMIS), a family of tools and services used to manage building and campus energy use. NREL's EMIS includes capabilities, such as benchmarking and monthly utility tracking, interval meter analytics, equipment fault detection and diagnostics, condition-based monitoring, and supervisory control, enabling unprecedented energy management capabilities. The system serves as a demonstration project for other federal facilities interested in learning about its design, features, and benefits.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Energy Management Information System Powers NREL's Intelligent Campus

EMIS↗

DOE OSTI2024

Maximizing Efficiency and Quality: Leveraging Automated Testing for Laboratory Commissioning

The traditional commissioning process uses sampling to select equipment for functional acceptance testing when large quantities of equipment are present. Although this approach is generally effective in identifying wide-spread issues, it has several shortcomings: it fails to evaluate equipment not included in the sample, provides only a one-time validation of equipment operation, and the standard documentation is a simple checklist of pass/fail questions. During the construction and commissioning process of the new Research and Innovation Laboratory (RAIL) in Golden, CO, the National Renewable Energy Laboratory team engaged Group14 Engineering to implement a Connected Commissioning process using fault detection and diagnostic software for automated functional acceptance testing. This presentation highlights the advantages offered by automated functional testing in this critical laboratory setting: (1) sampling 100% of BAS-connected equipment during functional testing, (2) testing results backed by data beyond the traditional pass/fail checklist, and (3) an automated test process that can be regularly executed by the building management team for ongoing commissioning throughout the life of the building. The presentation will also cover technical challenges associated with Connected Commissioning and the important conversations with key stakeholders that need to occur well before functional acceptance testing in order to successfully implement the automated testing processes.

automated testing↗

NASA NTRS2010

Ares I-X Ground Diagnostic Prototype

Automating prelaunch diagnostics for launch vehicles offers three potential benefits. First, it potentially improves safety by detecting faults that might otherwise have been missed so that they can be corrected before launch. Second, it potentially reduces launch delays by more quickly diagnosing the cause of anomalies that occur during prelaunch processing. Reducing launch delays will be critical to the success of NASA's planned future missions that require in-orbit rendezvous. Third, it potentially reduces costs by reducing both launch delays and the number of people needed to monitor the prelaunch process. NASA is currently developing the Ares I launch vehicle to bring the Orion capsule and its crew of four astronauts to low-earth orbit on their way to the moon. Ares I-X will be the first unmanned test flight of Ares I. It is scheduled to launch on October 27, 2009. The Ares I-X Ground Diagnostic Prototype is a prototype ground diagnostic system that will provide anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage thrust vector control (TVC) and for the associated ground hydraulics while it is in the Vehicle Assembly Building (VAB) at John F. Kennedy Space Center (KSC) and on the launch pad. It will serve as a prototype for a future operational ground diagnostic system for Ares I. The prototype combines three existing diagnostic tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool that is commercially produced by Qualtech Systems, Inc. It uses a qualitative model of failure propagation to perform fault isolation and diagnostics. We adapted an existing TEAMS model of the TVC to use for diagnostics and developed a TEAMS model of the ground hydraulics. The second tool, Spacecraft Health Inference Engine (SHINE), is a rule-based expert system developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification. The prototype uses the outputs of SHINE as inputs to TEAMS. The third tool, the Inductive Monitoring System (IMS), is an anomaly detection tool developed at NASA Ames Research Center and is currently used to monitor the International Space Station Control Moment Gyroscopes. IMS automatically "learns" a model of historical nominal data in the form of a set of clusters and signals an alarm when new data fails to match this model. IMS offers the potential to detect faults that have not been modeled. The three tools have been integrated and deployed to Hangar AE at KSC where they interface with live data from the Ares I-X vehicle and from the ground hydraulics. The outputs of the tools are displayed on a console in Hangar AE, one of the locations from which the Ares I-X launch will be monitored. The full paper will describe how the prototype performed before the launch. It will include an analysis of the prototype's accuracy, including false-positive rates, false-negative rates, and receiver operating characteristics (ROC) curves. It will also include a description of the prototype's computational requirements, including CPU usage, main memory usage, and disk usage. If the prototype detects any faults during the prelaunch period then the paper will include a description of those faults. Similarly, if the prototype has any false alarms then the paper will describe them and will attempt to explain their causes.

Schwabacher, Mark↗

DOE OSTI2020

Automatic Fault Detection & Diagnostics: Residential Market Analysis

This report provides an overview of the market potential for automated fault detection and diagnostics (AFDD) in the residential sector, focusing on embedded AFDD in central air conditioners (CAC) and air-source heat pumps (ASHP) as well as the use of smart diagnostic tools to ensure quality installation of CAC/ASHP equipment. The contents include background on AFDD, stakeholder engagement efforts, a technology assessment of AFDD and smart diagnostic tools, residential CAC and ASHP market trends, a characterization of the CAC and ASHP installed base, a synopsis of utility provider programs, and market barriers.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗