Bill Tschudi

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ALLIANCE MICROELECTRONICS WORKSHOPLBNL RESEARCH
UPDATE
Bill Tschudi wftschudi_at_lbl.gov
Lawrence Berkeley National Laboratory
Sponsored by Public Interest Energy Research
(PIER)California Energy Commission and
administered by California Institute for Energy
Efficiency (CIEE)
9-16-04
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Overview
Energy Intensive High-tech Buildings
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Overview
Update of Current Activities

• Cleanroom Activities
• Benchmarking and Best Practices
• Demand Controlled Filtration
• Fan-Filter Test Procedure
• Mini-Environments

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Overview
Current Activities, cont.

• Laboratory Activities
• Benchmarking and Best Practices
• Berkeley Fume Hood Development
• Overcoming Barriers (CAL/OSHA)
• Side-by-Side Testing
• 3 Industrial Demonstrations
• Labs 21

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Overview
Current Activities, cont.

• Data Center Activities
• Benchmarking and Best Practices
• Load intensity
• Performance Benchmarks
• Self-benchmarking Protocol
• Investigate UPS Efficiency Improvement
• Investigate Power Supply Improvement

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Overview
Current Activities, cont.

• Demonstration Projects
• LBNL role is to identify and scope possible
  demonstrations and arrange industry partners
• Technology Transfer
• Interaction with industry, e.g.
• ASHRAE
• SEMATECH
• IEST
• Cleanrooms East/West
• Public utilities emerging technology

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Benchmarking
Cleanroom Benchmarking

• Expanding the Database
• 4-6 New Case Studies
• Compare to Sematech Data
• Adding Data on UPS and Standby Generation

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Benchmarking
Recirculation Air Systems
LBNL Data

Average 3440
Sematech Data
Average 1953
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Benchmarking
Baselines Based Upon Benchmark Data

System Performance Target
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Benchmarking
Make-up Air Systems
LBNL Data
Average 972

Sematech Data
Average 946
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Benchmarking
Cleanroom Benchmarking
Air Change Rates

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Benchmarking
Standby Generation Loss

• Several Sources
• Heaters
• Battery chargers
• Transfer switches
• Fuel management systems
• Heaters alone (many operation hours) use more
  electricity than produced by the generator (few
  operating hours)
• May be possible to eliminate heaters, batteries,
  and chargers

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Benchmarking
Case Study
Recent case study demonstrated recirculation
setback
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Benchmarking
Recirculation Setback
Based Solely on Time clock, 800 PM -600 AM
setback No reported process problems or
pushback 60 70 Power Reduction on turndown
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Benchmarking
Recirculation Setback - Savings
Annual Fan Savings from Daily and Weekend
Setback 1,000,000 kWh130,000 -
150,000 Cooling load reduction when
setback 120 kW35 tons
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Benchmarking
Additional Savings Opportunities

• Currently using air cooled chiller at 1 kW/ton,
  partially to conserve water. The RO system
  rejects 2,500 4,000 gallons per day to sewer
  RO reject water can be used for tower makeup.
• Space humidity control exceeded design and
  process requirements in most spaces energy
  intensive dehumidification/reheat could be
  reduced by resetting humidity setpoints to
  design.
• Actively control recirculation setback for
  further fan savings.
• Reduce air change rates further.

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Demand Controlled Filtration

• Controlling Air Flow to
• Maintain Cleanliness
• Save energy by reducing fan speeds without
  degrading conditions in cleanroom
• Reduction of recirculation fan speed during
  unoccupied periods or periods of no activity
  (potential for minienvironments also)
• Demand filtration based on real-time particle
  concentration measurements
• Fan power proportional to the cube of the flow
  rate, so small changes can result in large
  savings

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Demand Controlled Filtration
Demand Controlled Filtration

• Pilot study completed - showing promise
• Collaboration with Cornell University
• Informal survey of ASHRAE TC 9.11 members
  regarding control of recirculation fan speed
• Many members said that they use some form of
  demand controlled filtration now
• Some have set backs during unoccupied periods
• Manual override is provided
• Demonstration partner identified
• Tool Manufacturer

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Demand Controlled Filtration

• Pilot Study
• ISO Class 5 cleanroom at LBNL monitored
  particle concentrations
• Three particle sensors controlling to
  various size particles
• Varied flow rate by controlling
  recirculation fan speed
• Room Pressurization not studied

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FFU Test Procedure
Fan-Filter Unit Testing

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FFU Test Procedure
FFU Goals

• Develop a standard way to test and report
  performance of Fan-Filter Units (FFUs)
• Promote FFU energy efficiency through use of
  the standard

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FFU Test Procedure
Test Procedure Development

• A team of experts provided peer-reviews of the
  draft standard procedure prepared by LBNL
• Project Advisors
• ITRI/AMCA
• FFU Manufacturers
• End-users
• Sematech

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FFU Test Procedure
On-going Development

• LBNL continues to work with IEST to provide
  assistance to its more comprehensive recommended
  Practice (RP) which will include testing for
  other characteristics such as vibration and
  noise.
• Any input to the draft standard will be
  appreciated.

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FFU Test Procedure
Planned FFU Activities

• Test Procedure will be tested at PGEs lab
  facility for small number of units
• Additional units to be tested depending upon
  funding available
• ITRI (Taiwan) test data may be useful
• PGE intends to establish baselines based upon
  tests and use the baselines in incentive
  programs. Other California public utilities can
  also use the baselines that PGE develops.

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Minienvironments
Minienvironment Tasks

• Understand the energy implications of using
  minienvironments micro and macro level
• Case study on minienvironment performance
  Asyst Technologies
• Work with IEST on Recommended Practice for
  minienvironments
• Identify and promote energy efficiency
  opportunities

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minienvironments
Planned Minienvironment Activities

• Develop strategies to improve efficiency based
  upon case study findings and other best
  practices input. Consider input from
• NEEA workshop attendees
• IEST
• Sematech
• Suppliers/Users/Utility
• A2C2/Cleanroom Magazines
• Host a workshop on minienvironment
  efficiency

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Data Centers
Data Center Benchmarking

Both LBNL and Uptime Institute found average IT
equipment loading at 25 W/ft2
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Data Centers
Data Center Benchmarking
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Power Supplies
Power Supplies in IT Equipment
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Power Supplies
Power Supplies in IT Equipment
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Power Supplies
Power Supply Efficiency

• Developed loading guidelines and test protocol
  for testing AC/DC power supplies for 1U, 2U and
  pedestal servers.
• Calculation tool for evaluating impact of
  improving power conversion process efficiency at
  rack level.
• Coordination with Server System Infrastructure
  (SSI) members to adopt loading guidelines and
  recommend higher efficiency levels for server
  power supplies.
• Evaluate real life server PS loading level and
  processor usage activity for servers.

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Power Supplies
Power Supply Efficiency
does not relate to very low power consumption
Very Low Processor Activity
Most of the time the GHz processor is doing
activities that can be done by a MHz processor
but the input power consumption is not changing
much
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UPS Systems
UPS System Benchmarking

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UPS Systems
UPS Measured Performance
Sample of 12 field measurements.
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UPS Systems
Measuring UPS efficiency to show impact of high
efficiency option.
Measured Result
Manufacturer Spec
On average, existing high efficiency modes can
make a 4 to 5 difference in UPS efficiency.
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UPS Systems
Analyzing UPS performance in high efficiency
option.
In high efficiency mode, there can be one cycle
(16.6 msec for 60 Hz) of voltage deviation on
the output of the UPS. Power supplies downstream
of the UPS can ride through this.
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UPS Systems
Labeling

• Efficiency and Reliability
• Data collection protocol.
• Technical review of efficiency versus load (based
  on specification) for current generation static
  and inertial UPS.
• Simplified calculation tools for comparing AC
  powering versus DC powering and evaluation of
  cost savings for higher efficiency UPS.
• Testing of UPS to show impact of high
  efficiency option on static UPS
• Coordinating with International labeling effort
  for quality efficiency.

Possible UPS Efficiency Labeling Criteria
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Demonstrations
LBNLs role

• Scoping demonstrations of technologies or
  strategies to improve energy efficiency in
  high- tech buildings
• Showcase New/Emerging or Under-utilized
  Technologies or Approaches

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Demonstrations
Possible Demonstrations

• Follow-on from current research tasks
• Demand controlled filtration
• Minienvironment efficiency improvement
• Fan-filter test procedure
• Fume hood demonstrations currently are
  proceeding

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Demonstrations

• Additional potential demonstrations for
  Cleanroom/Lab/Data Centers
• Airflow visualization via helium bubbles
• Combined Heat and Power
• UPS efficiency improvement
• Energy efficient vacuum pumps

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Technology Transfer
LBNL portal

Website http//hightech.lbl.gov
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Thank youQuestions?
9-16-04
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