by Fran Selvaggio

Executive summary
Laboratories face competing imperatives: the need to
maintain safety and compliance in air flows,
temperature and other environmental conditions, while
also reducing energy use and costs. While compliance
regulations get tougher, the Environmental Protection
Agency (EPA) estimates lab energy use could be
safely reduced by 30% or more nationwide. This paper
explains a four-step approach to driving and
maintaining energy efficiency in laboratory facilities.
998-2095-09-26-13AR0
 Four Steps for Improving Energy Efficiency in Laboratories

Introduction The U.S. Environmental Protection Agency estimates that reducing lab oratory energy use by
30%a goal it considers possiblewould reduce US national energy consumption by 84
trillion Btus. That represents a savings equivalent to removing 1.3 million cars from our
1
highways. Laboratories face unique challenges in order to achieve these goals. One
challenge is that laboratories are required to adhere to regulatory standards for
environmental conditions such as temperature and air quality. Another challenge is that most
labs lack of a standard approach for reducing energy use and costs.

Compared to an office building, the average laboratory consumes ten times more energy per
2
square foot (see Figure 1). Some labs use as much as 100 times more energy.

Lab owners and managers recognize these facts and are focused on improving energy
management. In fact, According to Tradeline, the # 2 priority for biocontainment facilities is
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controlling OpEx (behind safety through pressure & airflow control).

Of course, not all labs are the same. Some are stand-alone structures, and some are part of
a larger building or campus. High-containment labs, which work with potentially dangerous
biological agents, must meet higher standards for public safety and may be less concerned
with cost than a laboratory in a typical university or private research , where the primary
concern is to protect the research itself. Vivariums, or animal labs, have their own special
challenges related to the care of the animals.

Despite these differences, opportunities exist in nearly every lab to reduce energy use, while
improving compliance to required environmental standards. This paper explains a four -part
approach for driving and maintaining energy efficiency in laboratory facilities.

Figure 1
Energy use index by building
sector and site energy use in
laboratory buildings.

1
Laboratories for the 21st Century. 2010. Labs21 Benchmarking Tool.
http://labs21benchmarking.lbl.gov/
2
Kaushansky, Jeff Laboratories for the 21 st Century: Case StudiesPharmacia Building Q, Skokie,
Illinois. J. G. Maine Laboratories for the 21 st Century, 2002.
3
Tradeline, 2013 Priorities for Biocontainment Facilities, Dec 4, 2012,
http://www.tradelineinc.com/reports/2012-12/2013-priorities-biocontainment-facilities
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 Four Steps for Improving Energy Efficiency in Laboratories

While every laboratorys requirements are different and details will vary, experience has
shown that successful energy efficiency programs follow a four-part life cycle approach (see
Figure 2):

1. Energy audit and measure: Collect the data and analyze

2. Fix the basics: Deploy low cost, high yield fixes to blatant energy waste
3. Optimize through automation and regulation: Integrate energy management into
everyday processes through use of modern, high efficiency technologies
4. Monitor, maintain, and improve: ensure savings are embedded and sustained

These steps are best practice in any industry, but they are especially applicable to
laboratories, where environmental controls and associated energy use are both a significant
operational cost and a critical investment in quality and compliance.

The following sections illustrate how the four steps should be implemented in a laboratory
environment.

Figure 2
The energy management
lifecycle leverages the
deployment of both passive
and active efficiency best
practices

1. Energy audit Laying the foundation

and measure As the saying goes, You cant manage what you dont measure. Achieving an active energy
management model starts with the collection of data to monitor and measure how and where
energy is used.

In most laboratories, that means monitoring several utility types from primary sources such
as gas and electricity to secondary media such as steam, hot and chilled water, and
compressed air. Each has its associated energy cost and CO2 footprint. Gathering accurate
and relevant information from all of these utilities lays the foundation for an effective plan.

Data collection - Utility meter and billing data is a good starting point. This can be useful for
identifying standing load or idle time consumption and reviewing tariff suitability, but gives
only a highly aggregated view without the granularity necessary to pinpoint energy waste. To
generate more useful information, a metering strategy should be developed that m ay include,
for example, the ability to account for 90% of energy by end-use type, provide individual
metering of loads and feeders of a certain size, and monitor all energy streams by lab facility

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 Four Steps for Improving Energy Efficiency in Laboratories

or department. Companies should plan for rolling out metering to existing equipment and set
standards for new lab purchases.

Modern meters can facilitate remote automatic data collection. Often existing site networks or
wireless technology can be used to concentrate data and share it with users via dedicated
PCs or web-based tools. This simplifies the process of gathering energy consumption data as
well as richer information useful for site operations such as electrical maximum demand and
power qualityboth of which can have their impact on energy costs.

Auditing - Further data collection should be managed through structured audits of the
existing facilities, with clearly defined scope and deliverables. Audit approaches can range
from a one or two day walkthrough of key energy consuming areas, to a comprehensive audit
with detailed recommendations and estimates for energy saving opportunities. Whatever
approach is taken, audit outcomes should focus on producing an energy action plan that
includes detailed costs and savings potential.

Performance contracts - It is often possible to guarantee savings through a performance

contract. Under this scenario, the risk and reward is shared with the supplier. Following an
audit, an energy action plan is developed and savings opportunities estimated and evaluated.
The savings generated from implementing the plan are used to help pay for the cost of the
capital equipment over a specified number of yearsminimizing the financial risk to the
organization. This approach necessitates a higher level of monitoring before and after
interventions, with a higher level of involvement from both parties and a more detailed
contractual agreement.

2. Fix the Upgrade and improve to reduce losses

basics Once energy data has been captured and analyzed, the next step is to use that data to
reduce energy waste. Laboratories often start with the basics: using passive energy efficiency
measures to reduce losses from energy consuming devices. A variety of technologies exist to
help improve energy efficiency. Examples of passive energy efficie ncy approaches include:

Low energy lighting

Low loss transformers
High efficiency motors

The importance of motors - Motors should be a major focus of energy efficiency measures,
since they typically consume a large percentage of the electrical energy in a lab facility, much
of it related to HVAC systems. New motor efficiency standards have attempted to unify the
various approaches around the world and now provide benchmarks used by governments to
legislate on minimum efficiency performance standards. Howe ver, these generally only apply
to new motor purchases. In some cases legislation is phased in over many years and there
are generous extensions to allow for depletion of existing stocks. Laboratories should create
a motor management policy to improve the efficiency of this significant asset base, including:

Audits to understand the existing asset base and benchmark against current high
efficiency standards
Identify motor efficiency upgrade opportunities
Determine a repair/replace policy (note that rewound motors typically lose 1 to 1.5%
efficiency each time)
Dont rely on long lead in legislation update specifications for high efficiency motors
and include those for OEM purchased equipment. A motor running 24/7 may well
consume the equivalent of its capital cost in energy, within weeks

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 Four Steps for Improving Energy Efficiency in Laboratories

The human factor - Any energy efficiency program must also address the human aspect
peoples activities and actions have a real impact on the consumption of energy. Employees
need to be engaged and their cooperation and expertise harnessed. This can be done in a
variety of ways, from awareness programs and incentive contests, to formal training on
procedures. The exact approach will vary for each laboratory and location, but the key is to
remember that energy efficiency is not just an equipment issue; it is a behavioral issue as
well. Motivating and educating employees will improve the effectiveness of any energy
efficiency action.

3. Optimize Active Energy Efficiency

through The passive measures described in Step 2 are important to implement. However, to have an
effective energy management program, active energy efficiency should be embedded into the
automation laboratory through automated control systems.

and control Active energy reduction is challenging in laboratories, where maintaining the proper
environment is critical to safety, compliance and research success. This is especially true for
high-containment laboratories, where there is an overriding need to ensure containment of
highly pathogenic organisms and to meet rigorous regulatory standards.

But with careful measuring and auditing, it is usually possible to find energy waste that can be
safely eliminated, without harming compliance or quality in any way. Real auditing examples
of energy waste include basic problems such as heating and cooling demand fighting,
humidity controls set much lower than tolerances require, and no set back to temper
conditions for when the lab is not in use. Correcting such problems can yield significant
savings, often for little investment.

Optimize air flow rates - Air flow systems are especially critical in laboratories, where 100%
fresh air is often required, with additional filtering, treating and conditioning to maintain the
correct temperature and humidity. In many labs, ventilation systems alone can account for up
to 80% of the energy consumption.

Much of this energy use can be safely reduced, with the proper monitoring and controls.
Often, actual flow rates are much higher than design requirements, a nd sometimes even the
design flow rates are higher than needed due to change of use.

Variable speed drives - Control of motor speed, using variable speed drives (VSD), is the
most effective way to manage air flow rates. VSDs are easy to retrofit with mini mal disruption.
Flow rates can be controlled either directly at the VSD or through the building management
systems (BMS). Typically, pressure sensors are used to control flow, enabling automated
changes to be made according to requirementsfor example, full design flow rate when the
laboratory is being used and relaxed levels for down periods. Pressure sensors fitted across
a filter can trigger increased fan speed to adjust for the degradation of the filter. Control
systems can be set to provide a maintenance alert when it becomes economical to change
the filter and so reduce the fan power.

Integration with building automation - When making decisions about a labs air flow rate,
remember that very few labs exist in a sealed environment. Air flow in the lab is affected by
air pressure and conditions in the building where the lab resides. Best practice today is to
integrate lab systems with other building automation systems, to optimize both overall air flow
performance and energy use.

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 Four Steps for Improving Energy Efficiency in Laboratories

Improve the exhaust system - Exhaust systems merit particular attentionthey comprise
up to 40% of the ventilation system's energy use, and as much as 30% of a lab's total energy
4
consumption.

The good news is that, by using automated monitoring and control systems; it is often
possible to safely reduce energy use in lab exhaust systems by as much as 50%, which
would reduce a lab's total energy use by 15%.

Accurate set points - Exhaust systems in labs are typically maintained at full power on a
constant basis24x7 in many labs. Furthermore, these settings are usually based on worst-
case scenarios for wind conditions and contaminants. In the case of wind, for example, the
most extreme conditions rarely occur. And in the case of contaminants, the EPA states that:
"An overly conservative judgment about the potential toxicity of an exhaust stream may result
in a high-energy-use exhaust system as volume flow or exit velocity is increased
unnecessarily." The agency recommends that exhaust flow be based on scientific
measurements of actual contaminants, adjusting exhaust flow accordingly to achieve "an
exhaust system that yields acceptable air quality while consuming a minimum amount of
By using automated 5
energy."
monitoring and control
systems; it is often For example, based on the experience of operating research labs that have used air qualit y
possible to safely reduce monitors in their exhaust flow, it has been found that worst -case airflow rates are needed only
energy use in lab exhaust about 12 hours per yearwhich means that lower set points could be used, if proper
systems by as much as monitoring were in place, as much as 99% of the time. One laboratory was ab le to reduce
50%. exhaust-related energy use to just 10% of previous levels, through the use of a staged
variable-air-volume (VAV) system with anemometer control. This resulted in annual savings
of $81,000, plus an additional bonus of $90,000 from the utility c ompany for the conservation
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measures.

Manifold exhaust systems - According to Laboratories for the 21st Century, a manifold
exhaust system should be used where possible. This approach, with a primary fan and a
backup unit in a common duct system, is more efficient than separately ducted, multiple
exhaust fans. A paper from their web site names four ways a manifold exhaust system saves
energy:

Reduces fan power

Provides adjustable airflow that can modulate energy use to varying requirements
Requires less energy to disperse exhaust plumes
Increases energy recovery opportunities

Experience has shown that during laboratory retrofit projects, manifold exhaust systems
reduce construction costs and help avoid operational disruptions.

Pumping systems - Variable speed drives, mentioned previously, can also provide
significant energy savings in pumping systems by varying flow rates according to system
demand instead of operating at a fixed volume. Common applications include chilled and hot
water distribution to air handling units and cooling towers.

4
Environmental Protection Agency, Best Practices: Modeling Exhaust Dispersion for Specifying
Acceptable Exhaust/Intake Designs. Laboratories for the 21st Century, Environmental Protection
Agency2005 DOE/GO-102005-2104. http://www.i2sl.org/documents/toolkit/bp_modeling_508.pdf
5
Reifschnieder, Jeff D., Carter, John J., Cochran, Brad C," Saving Energy in Lab Exhaust Systems",
ASHRAE Journal, June 2011
6
Manifolding Laboratory Exhaust Systems, Laboratories of the 21st Century Best Practices Guide,
http://www1.eere.energy.gov/femp/pdfs/bp_manifold_508.pdf
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 Four Steps for Improving Energy Efficiency in Laboratories

Occupancy monitoring - Occupancy monitoring is another way to use variable controls.

Simple presence detectors, CO 2 monitors, and access control systems can be used to control
lighting and HVAC systems dependent upon changing use. Occupancy monitoring may not
be possible in many labs (such as vivarium labs), or may be limited to certain areas of a
building. Where practical, however, this approach can yield important savings.

4. Monitor, Ensure the benefits are sustained

maintain and Energy efficiency is not a one-time project, but a never-ending process of continual
monitoring, maintenance, and improvement. Otherwise, the savings from the initial project will
improve diminish over time.

For example, while robust automation, control, and monitoring can deliver savings of up to
30%, evidence suggests that 8% of these savings are lost annually without appropriate
monitoring and maintenance (see Figure 3). There are many reasons for this, from changing
conditions to human activities. For example, audit experience has regularly found control
systems that are bypassed, perhaps sometimes for good short-term operational reasons.
However, these overrides can accumulate astonishing levels of energy waste over time.

Managing ongoing performance is not without challenges. Many labs have seen maintenance
resources and budgets shrinking, so their focus tends to be on the elem ents critical to their
mission, and the utility systems may be neglected. Even with regular maintenance checks
(which typically happen annually at best), equipment failures may go unnoticed for many
months or longer.

To ensure the continuing efficacy of all energy saving measures, management must commit
to a vigorous program of actively monitoring data from the lab, analyzing and identifying
anomalies, and then acting upon this information in a timely manner.

Modeling lab performance - An important key to ongoing monitoring is to understand the

performance of the facility as whole. This is a complex task, because it involves the
correlation of a number of variables. For laboratory HVAC systems, the weather impacts
energy consumption by affecting heating, cooling, and humidification requirements. Facility
utilization and occupancy also have an impact.

Figure 3
Initial efficiency gains can be
undermined if no attention is
paid to proper monitoring and
maintenance

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 Four Steps for Improving Energy Efficiency in Laboratories

Correlating all of the appropriate variables in energy consumption results in a powerful model
that can be used as a tool to witness what is actually happening. Modern monitoring and
targeting software provides analysis tools to build such models. Th ese tools may vary from
simple regression analysis to multi-variable models with step functions. The step function is
particularly suited to correlating energy usage with outside temperatures, to reflect the
change between heating and cooling in response to external conditions. This can reveal how
well HVAC system controls are functioning and how effectively control dead bands have been
set.

Establishing a model for the laboratory provides an independent baseline for future energy
management actions. It also provides a basis for targeting and monitoring energy savings at
the facility, department or equipment level. This normalization allows accurate tracking of
savings when making before and after comparisons of energy improvement
implementations.

Most importantly, lab behavior can be monitored, and unwarranted increases in energy
consumption can be identifiedwhich might have otherwise gone unnoticed. Lab managers
become well informed and armed to root out and rectify any problems which may arise,
whether from system failure, control settings, or worker-based behavior.

The resource challenge - Even well designed systems require a level of maintenance and
regular review to ensure they remain optimally set for the ever-changing circumstances of the
modern laboratory facilityand this requires staff resources that may be scarce or stretched
too thin.

Building Management Systems (BMS) tightly integrated with laboratory air -flow control
systems can help. These systems, which provide control and automation fu nctions for a
facilitys plant, can also provide essential monitoring capability to identify energy issues and
anomalies. Any competent system will provide comprehensive alarming functionality, but
often a certain level of expertise is needed to interrogate the system on a routine basis to find
deeper rooted problems and energy waste.

One solution is to outsource this expertise and use a remote bureau to monitor energy
management systems (EMS) and BMS. These can provide services on a 24x365 basis, such
as:

Energy reporting and dashboards

Alerting for anomalous consumption
Expert analysis and reporting on energy saving opportunities
BMS alarm handling and reporting, and even maintenance response services triggered
by the alarms, without end user intervention
BMS optimization services

Whether or not outside resources are used, an effective approach to monitoring will focus on
those maintenance efforts that are most important and promise the greatest return, thus
ensuring the effective use of finite resources.

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 Four Steps for Improving Energy Efficiency in Laboratories

Conclusion Energy has become a major business factor in laboratories and will remain so for the
foreseeable future, for reasons of cost, compliance and good public citizenship.

Laboratories striving to excel in energy efficiency, whether for cost savings or meeting their
environmental goals, will reach a point when significant capital expenditure (CapEx) is
necessary. Typical investments of this type include higher high-efficiency chillers or boilers,
combined heat and power plant, or one of the many renewable energy generation
technologies.

The steps outlined in this paper will ensure that these investments are in support of optimized
and sustainable loads, and that further investments will produce the predicted benefits.
Energy planning thus increases the reliability and confidence in critical CapEx decisions, by
providing a strategic rationale with the supporting data to back it up.

By following the four steps that comprise best practice energy management energy audit
and measure; fix the basics; optimize through automation and regulation; monitor, maintain
and improvelaboratories can excel at energy efficiency and cost reduction. At the same
time, they help ensure and document that energy programs are sustainable, and meet qualit y
and regulatory requirements.

Energy management is not an easy process and requires time and effort. But experience has
shown that laboratories that adopt an active energy efficiency approach combined with the
commitment in cost and resources have seen their efforts pay off handsomelyin reduced
energy cost and waste, improved efficiency, and long-term sustainability.

2013 Schneider Electric. All rights reserved.

About the author

Fran Selvaggio is a Global Application Engineer for Schneider Electric's Life Sciences
solution team. He holds bachelors degrees in Mechanical Engineering from Northeastern
University. Previous to his career with Schneider Electric, Mr. Selvaggio served as a
Consultant and Project Engineer for Amgen. He also lived in Singapore for 5 years where he
worked for Merck Sharp & Dohme as a Project Engineer for Building Automation and
Security Services.

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