Climate Management System for Corrosion Control Facilities

EW-201345

Objective

The Building 59 (B59) Corrosion Control Facility (CCF) at Robins Air Force Base (AFB) in Warner Robins, Georgia, is used for paint removal and application for C-5, C-17, and other similar-sized aircraft. Recent audits at B59 have identified cost savings opportunities of at least $150 thousand per year in electricity and gas savings by operating the building in the correct building mode (paint, cure, nonchemical, etc.) and other utilities saving opportunities generally related to energy management rather than inherent equipment inefficiencies. The overall objective of this project is to capture these cost and energy savings using a novel Climate Management System (CMS), based on Geosyntec’s recently developed Real Time Control and Monitoring Information package (OptiRTC™), in the challenging work environment of B59, resulting in environmental conditions that also maintain or improve personnel health and safety, work flow, and product quality while meeting environmental regulations. The CMS will increase the ability of B59 personnel and other stakeholders to identify, prioritize, and effectively communicate needed maintenance, system upgrades, and other energy savings opportunities.

Back to Top

Technology Description

The CMS is based on augmenting (rather than replacing) the traditional controls system with a management approach that processes, manages, analyzes, and effectively communicates disparate data streams with customized, intuitive graphics and familiar computer interfaces, distinguishing the CMS from conventional energy management approaches that may not always address the hurdles of interacting with complex data and analysis. The grid-based, object-oriented layout is intuitive to non-programmers so that Geosyntec’s engineers, and ultimately the end-users, can rapidly improve upon the graphical presentation of client dashboards without engaging a specialized programming team, resulting in high-quality, adaptable, and user-tailored data views. It runs inside a security boundary that limits interactions with the end-user’s computer. Data exchange employs asymmetric cryptography to initialize communication sessions, symmetric encryption for privacy within those sessions, and message authentication codes to provide assurance of the integrity and source of each data message. This secure approach is comparable to that used by Microsoft to provide businesses access to cloud platform computing resources. In addition to improved control functionality, the CMS uses analytics necessary for fault detection and diagnosis (FDD). In many buildings, 20% or more of building energy is wasted when equipment is improperly operated or poorly maintained. Such waste often goes unnoticed since the system performs the desired functions, albeit at greater cost. The team has developed algorithms for automatically identifying such issues using non-intrusive load monitors (NILMs), an energy-monitoring device that measures electrical current. Through careful analysis of electrical data using NILM algorithms, critical faults can be detected while still in an incipient phase.

Back to Top

Benefits

Augmentation of existing controls systems allows the CMS to be readily translated to other Department of Defense (DoD) facilities. Corrosion control operations offer some of the most technically challenging deployments. Successful demonstration of the CMS at Robins AFB should lend itself to implementation at both large CCFs (e.g., the B-52 Corrosion Control Hangar at Tinker AFB; the C-17 Corrosion Control Hangar at Charleston AFB; and the C-130 Corrosion Control Hangar at Hill AFB) as well as non-CCFs worldwide. CCFs tend to use a substantial fraction of the electricity and gas at the base – for example, B59 uses approximately $1.7 million in electricity and $250 thousand in gas annually, representing about 7 to 8% of the utility costs for the entire Robins AFB. Energy savings of just 10% (already identified by recent B59 audits) represent annual savings of about $200 thousand per year at this demonstration site alone and millions of dollars when similar savings are scaled to DoD facilities worldwide. The use of cloud computing services to support the CMS deployment is an early example of the potentially significant strategic benefits to DoD gained through web-driven approaches for low-risk information management at DoD facilities. (Anticipated Project Completion - 2016)

Back to Top

Points of Contact

Principal Investigator

Dr. Brian Adair

Geosyntec Consultants

Phone: 704-227-0848

Fax: 678-202-9501

Program Manager

Energy and Water

SERDP and ESTCP

Document Types

  • Fact Sheet - Brief project summary with links to related documents and points of contact.
  • Final Report - Comprehensive report for every completed SERDP and ESTCP project that contains all technical results.
  • Cost & Performance Report - Overview of ESTCP demonstration activities, results, and conclusions, standardized to facilitate implementation decisions.
  • Technical Report - Additional interim reports, laboratory reports, demonstration reports, and technology survey reports.
  • Guidance - Instructional information on technical topics such as protocols and user’s guides.
  • Workshop Report - Summary of workshop discussion and findings.
  • Multimedia - On demand videos, animations, and webcasts highlighting featured initiatives or technologies.
  • Model/Software - Computer programs and applications available for download.
  • Database - Digitally organized collection of data available to search and access.