111 III III A11104 551312

NBSIR 79-1709

Volume Nine HUD UTILITIES

DEMONSTRATION

SERIES

DESCRIPTION OF THE DATA ACQUISITION

AND INSTRUMENTATION SYSTEMS: JERSEY

CITY TOTAL ENERGY PROJECT

Center for Building Technology

National Engineering Laboratory

National Bureau of Standards

Washington, D.C. 20234

MODULAR INTEGRATED UTILITY SYSTEMS

improving community utility services by supplying

electricity, heating, cooling, and water/ processing

liquid and solid wastes/ conserving energy and

natural resources/ minimizing environmental impact

Prepared for:

Department of Housing and Urban Development

Energy, Building Technology and Standards Division

Office of Policy Development and Research

Washington, D.C. 20410

March 1979

, 1)56

79-1709

JiaMonaJ Bureau m 1 4

fvOt a <

NBSIR 79-1709

DESCRIPTION OF THE DATA ACQUISITION

AND INSTRUMENTATION SYSTEMS: JERSEY

CITY TOTAL ENERGY PROJECT

Charles Bulik

William G. Rippey

C. Warren Hurley

Daniel E. Rorrer

Center for Building Technology

National Engineering Laboratory

National Bureau of Standards

Washington, D.C. 20234

March 1979

Prepared for: U.S. Department of Housing and Urban Development

Energy, Building Technology and Standards Division

Office of Policy Development and Research

Washington, D.C. 20410

U.S. DEPARTMENT OF COMMERCE, Juanita M. Kreps, Secretary

Jordan J. Baruch, Assistant Secretary for Science and Technology

NATIONAL BUREAU OF STANDARDS, Ernest Ambler, Director

0t

Table of Contents

Page

Abstract 1

1. INTRODUCTION 1

1.1 Site Description 1 1.2 Total Energy Plant Description 2 1.3 NBS Instrumentation and Data Acquisition System 3

2. MEASUREMENT OBJECTIVES AND MAJOR SITE COMPONENTS 3

2.1 Engine-Generator Measurements 3

2.2 Primary Hot Water Loop 4

2.3 Boiler 4

2.4 Chiller 4

2.5 Secondary Hot Water 5

2.6 Electrical System 5 2.7 Site Buildings 6

3. INSTRUMENTS USED AT THE TOTAL ENERGY SITE 6

3.1 Electrical Instrumentation 6

3.2 Fluid Flow Instrumentation 7 3.3 Temperature Instrumentation 9

3.4 Alarm Sensors 10

3.5 Weather Station 11

4. DATA ACQUISITION SYSTEM 11

4.1 Site Requirements 11

4.2 DAS Description and Data Sampling Rationale 12

4.3 DAS Capabilities and Data Handling 15

5. SYSTEM OPERATION 16

5.1 Inputs 16

5.2 Outputs 16

5.3 Scanning Speed 17

5.4 Operational Modes 20

6. MAJOR SYSTEM COMPONENTS 21

6.1 Digital Clock 21

6.2 Slave Scanner 22

6.3 Remote Slave Scanner 22

6.4 Scanner Control 23

6.5 System Controller 23

6.6 Digital Voltmeter 24

iii
Page

6.7 Data Coupler 24

6.8 Digital Tape Recorder 25

7. DATA HANDLING 26

7.1 Output Format 26

7.2 Data Editing and Conversion 26

8. DAS AND INSTRUMENTATION COSTS 27

8.1 Instrumentation Design Costs 28

8.2 Equipment Purchase and Installation Costs 28

8.3 NBS Check Out Costs 31

9. SENSOR SELECTION AND ACCURACIES 35

10. INSTRUMENTATION PROBLEMS 39

10.1 Electrical 39

10.2 Water Flow 41

10.3 Fuel Flow 42

10.4 Temperature 43

10.5 Alarm 44

10.6 General Remarks 44

ACKNOWLEDGMENTS 46

FIGURES 47

REFERENCES 99

Appendix 1: As-Built Drawings of Site Facilities and Instrument

Locations. A1

Appendix 2: Data Acquisition List: A listing of all data channels by

channel number and NBS code number. A2

Appendix 3: Specifications for the NBS Data Acquisition System. A3

Appendix 4: Venturi Flow Calibration Report A4

iv
DESCRIPTION OF THE DATA ACQUISITION AND INSTRUMENTATION SYSTEMS:

JERSEY CITY TOTAL ENERGY PROJECT

by

Charles Bulik, William G. Rippey, C. Warren Hurley, Dan E. Rorrer

ABSTRACT

Under the sponsorship of the Department of Housing and Urban Development

(HUD), the National Bureau of Standards (NBS) gathered engineering data on an operating diesel total energy plant which supplies all electrical

power, hot water, and chilled water to a 485 unit apartment/commercial

building complex in Jersey City, New Jersey. Engineering data was continuously collected from April 1975 to December 1978 by a data acquisition system (DAS) which recorded the outputs from approximately 200

sensors located in the plant and site buildings.

This report describes the design and operation of the instrumentation

system and the data acquisition system used to monitor the total energy

plant and certain utility services to the site buildings. The report

contains a description of the types, characteristics and locations of

instruments used to measure physical variables. The capabilities and

operational modes of the data acquisition system are discussed and the

major data acquisition system components are described in detail. The

report also contains a brief description of the total energy plant and

site, instrument costs, data processing procedures and some of the

instrumentation problems encountered.

Keywords: Data acquisition system; Digital tape recorder; Fuel

measurement; Instrumentation; Total energy; Transducers;

Weather station

v
.
DESCRIPTION OF THE DATA ACQUISITION AND INSTRUMENTATION SYSTEMS:

JERSEY CITY TOTAL ENERGY PROJECT

Charles Bulik, William G. Rippey, C. Warren Hurley, Dan E. Rorrer

1 . INTRODUCTION

The instrumentation and data acquisition system described in this report was used to collect data on energy use and total energy plant operation

on an apartment building complex (Summit Plaza) in Jersey City, New

Jersey. The total energy plant produced all electricity, space heating,

domestic hot water heating and chilled water for air conditioning ser- vices used on the site. The development and construction of the Jersey

City site was directed by the Department of Housing and Urban Development (HUD) under its Operation Breakthrough program. The Operation

Breakthrough program initiated innovative housing projects throughout

the United States. The total energy plant was developed, contracted and

operated by HUD, under its utilities program.

Under contract to HUD, the National Bureau of Standards designed and

installed a data acquisition system (DAS) and the instrumentation to

gather data for an evaluation of the economy, efficiency and reliability

of the total energy system.

1.1 SITE DESCRIPTION

The Jersey City site included a total energy plant serving the residential complex of 485 dwelling units in four medium to highrise apartment

buildings, an elementary school (kindergarten through grade 3), a business building (with 46,000 square feet of commercial space) and a swimming pool. A central equipment building (CEB) housed the total

energy plant and the collecting apparatus for a site pneumatic trash

collection system.

Disc la imer

Certain commercial equipment and instruments are identified in this

paper in order to adequately describe the capabilities and technical

features of hardware used in the instrumentation system. In no case

does such identification imply recommendation or endorsement by the

National Bureau of Standards, nor does it imply that the material or equipment identified is necessarily the best available for the purpos

1
Figure 1 is an aerial photo of the site and surrounding area. Figure 2

is a plan view drawing which identifies the site buildings. The first

apartment tenant moved into the site in March 1974, and apartment occu- pancy was at 96 percent by October 1974. The first commercial tenant

moved into a storefront on Kennedy Boulevard in October 1975, and the

first school session began in September 1976.

1.2 TOTAL ENERGY PLANT DESCRIPTION

The total energy plant, figure 3, consisted of five 600 kW diesel enginegenerators, figure 4, two 13.4 MBtu/hr (4.0 MW) hot water boilers and two

546 ton (1.9 MW) absorption chillers. The engine-generators and boilers

used #2 fuel oil from three 25,000 gallon (95,000 £) underground storage

tanks. A pneumatic trash collection system moved trash from apartment

building deposit chutes through an underground pipe to the central equipment building where the trash was compacted and removed from the site by

trash disposal trucks.

In conventional electrical power generation stations, engine-jacket heat

and exhaust gas heat are expelled into the atmosphere as waste. At the

Jersey City site, a closed primary hot water (PHW) loop recovered heat

from the engine- jacket and exhaust heat exchangers to supply the space

heating, cooling and domestic hot water heating needs of the site. When

the plant or site thermal energy demands exceeded that produced by the

plant engine heat recovery, auxiliary boiler(s) were put into service.

Figure 5 shows the primary hot water loop circulation through the

engines, boilers, chillers, heat exchangers, dry coolers and emergency

heat exchanger. Two pumps circulated the 180° to 230°F (82° to 110°C)

primary water at a rate of 11,000 Ibs/min (500 kg/min)

.

Heat recovered by the primary hot water loop was used to meet the thermal

energy needs of the site. The site heat exchanges in the plant transferred heat from the primary hot water loop to two secondary hot water

loops. Secondary hot water was circulated to site buildings to provide

space heating in the winter and to heat domestic hot water year round.

During the summer, PHW circulated through one or both of two absorption

water chillers producing 45°F (9°C) chilled water for CEB and site air

conditioning needs. A four-pipe system circulated hot and chilled water

to site buildings through underground insulated piping. When thermal

energy demands for the site and chillers were very low, a forced convection dry surface heat exchanger (dry cooler) released excess PHW heat to

the atmosphere to control the PHW temperature and prevent overheating of

the engines. An emergency heat exchanger using city water backed up the

dry cooler.

Electrical power generated by the total energy (TE) plant was distributed

to the site through two separate feeders to each building; an essential

power feeder and a normal power feeder. In the event of a complete TE

plant electrical outage, the essential feeder only was automatically

switched to the local utility power bus to maintain operation of site

emergency lighting, fire protection systems, elevators and plant engine

2
startup and support equipment. Figure 6 shows the power feeder arrangements in the CEB.

1.3 NBS INSTRUMENTATION AND DATA ACQUISITION SYSTEM

The Jersey City site was instrumented with 223 transducers measuring

and converting physical variables into electrical signals that were

recorded on magnetic tape by the Data Acquisition System (DAS). The DAS

recorded data every five minutes, 24 hours a day and completed a scan of

all 223 instruments in 30 seconds. A data tape reel was removed from

the site periodically, about every week and returned to the NBS where

it was processed on a mini-computer to produce information on site operation, efficiency and reliability. The rationale for a five minute sam- pling interval and a 30 second scanning speed is presented in Sections

4 and 5.3, respectively. Section 2 discusses measurement objectives.

Section 3 describes, in detail, the instruments used at the site.

Sections 4, 5, and 6 describe the DAS capabilities and operation. Section 7 describes data handling and Section 8 and 9 indicate instrument

costs, selection and accuracies.

2. MEASUREMENT OBJECTIVES AND MAJOR SITE COMPONENTS

When the Jersey City Breakthrough site was selected by HUD to be the

demonstration Total Energy site the NBS prepared an evaluation plan and

conducted a study of the site architectural plans, power plant design

and site plumbing and electrical distribution plans to determine the

number and types of instruments that would be required to obtain the

measurements necessary to perform the site evaluation. The following

three areas were addressed: overall site energy use, the energy efficiencies of the plant and its components, and the reliability, quality

and economics of the utilities supplied by the plant. From this study

of site layout and methods of distribution of heat, water, cooling and

electrical power the 200 plus measurements necessary to provide sufficient data for an evaluation of the total energy site were identified.

Fuel oil, stored in underground tanks, was the single energy source for

the Jersey City site. An evaluation of operating efficiency and reliability calls for the measurement of: fuel consumption by the plant

engine-generators and boilers, hot water and chilled water flow rates,

gross generated electrical power, heat and power consumption by the

dwelling complexes and by the plant support equipment. A record of site

weather conditions, temperature, humidity and solar radiation, provided

a means for correlation between site energy demand and weather conditions. The following sections, 2.1 through 2.7 identify the major site

components and the parameters that were measured.

2.1 ENGINE-GENERATOR MEASUREMENTS

The engine-generator units were instrumented to determine the fuel con- sumed and rate of fuel consumption, electrical power generated, heat

transferred to the water jacket and heat lost in the exhaust gases.

3
From these measurements the efficiency of the engines and amount of heat

recovery could be determined.

Each engine generator unit consisted of a 600 kW generator driven by a water-cooled, V-12 turbocharged/after-cooled diesel engine fueled with

number 2 fuel oil. The generators supplied three-phase, 60 hertz electrical power through a 4-wire "Y" system at a line voltage of 480 volts

(figure 6). Thermal energy was recovered from the engine jackets and

exhausts

.

The five engine-generators fed a main power bus. The main bus was instrumented to measure the total electrical power (gross power), line

voltage, frequency, and power factor. Measurements were also made of

the total fuel consumed by the bank of five engines, primary hot water

flow, primary hot water temperature rise across the engine bank and the

water temperature at the engine inlet. The DAS was designed to receive

malfunction signals from each engine-generator unit. Figure 7 illustrates

the engine-generator instrumentation system. Since all five enginegenerators were the same model and tests conducted at the Caterpillar

factory prior to installation indicated nearly identical performance,

only units one and two were equipped with additional instruments to

measure electrical power output, jacket water temperature, exhaust heat

exchanger temperature, lubrication oil/after-cooler temperature, exhaust

gas temperature, engine running time, lubrication oil temperature and

oil pressure (see figure 8).

2.2

PRIMARY HOT WATER LOOP MEASUREMENTS

The thermal energy flowing into and out of the primary hot water loop was determined by measuring the water flow rate in the loop and the

differential temperatures across the engines, boilers, heat exchangers

and chillers. Figure 9 shows the major heat exchange units within the

primary hot water loop and the measurement points.

2.3

BOILER MEASUREMENTS

Hot-water boilers, burning #2 fuel, supplied thermal energy to the primary hot water loop (PHW) whenever the PHW temperature dropped to 180°F.

The energy into the boiler was determined by measuring the fuel consumed

by the boilers and having the computer calculate the energy from the

Btu's per gallon and the measured gallons. The actual thermal energy

transferred to the PHW loop was determined by measuring the differential

temperature across the boilers and the primary hot water flow rate.

Exhaust stack gas temperatures were measured to determine energy losses

through the stacks. Figure 10 shows the primary water flow through the

boiler units and the measurement points.

2.4

CHILLER MEASUREMENTS

The two absorption chillers used primary hot water to generate chilled

water at 45°F (7°C) for air conditioning of the plant and site buildings.

The system was usually in operation from May through October. To

4
calculate the performance of the absorption chiller system, the measurement system provided data to determine the energy input from the PHW

system, the energy output to the chilled water system, and the energy

rejected through the cooling tower system. Referring to figure 11, a flow diagram of the chilled water system, the thermal energy input was

obtained by measuring the PHW flow and the differential temperature at

the inlet. Thermal energy output was calculated from the chilled water

flow rate and the inlet-outlet temperature difference. The cooling tower

thermal energy losses were, similarly, a product of the water flow rate

and differential temperature. The chiller measurement points were specifically chosen to permit a calculation of coefficient of performance of

the system and each chiller. The amount of thermal energy (as chilled

water) being delivered to the East zone and West zone buildings was also

measured as indicated in figure 11. The East zone contained the Pool,

School, Shelley A and Shelley B buidlings. The West zone included Camci,

Descon and Business buildings (see figure 2 for a plan view of the

site)

.

2.5 SECONDARY HOT WATER

The secondary hot water loop receives heat from the primary hot water

loop through two heat exchangers that are located in the CEB. The SHW

circulates from the CEB to the site buildings. The thermal energy supplied to the heat exchangers by the PHW loop was determined from the

flow rate and differential temperature measurements indicated in

figure 12. The thermal energy delivered to the site buildings was determined from flow and temperature measurements made in the secondary hot

water loop (figure 12).

2.6 ELECTRICAL SYSTEM MEASUREMENTS

Three phase, 60 hertz electrical power was distributed at a line voltage

of 480 volts to the site buildings and to pumps and motors within the

power plant.

Figure 13 shows a schematic of the electrical distribution system and

the measurement points. The generator main bus branched into two feeder

busses, a normal and an essential bus. The normal feeder provided electrical power for electric cooking ranges, ventilation, apartment and

office lighting and applicances in the site buildings. The chillers,

exhaust fans, and hot water pumps not directly involved in the PHW loop

operation (through motor control centers MCC-2 and MCC-3) and the central

pneumatic trash collection system (PTC) are also on the normal bus. The

essential load bus provided electrical power to the plant through MCC-1

(see Figure 14) and to branches that service plant lighting, site emergency lighting, site fire protection, site elevators, boilers, dry

coolers, pumps directly related to the PHW loop, electrical control

equipment, and the NBS instrumentation system. In the event of electrical plant outage, essential loads were automatically switched to the

local electric utility (Public Service Electric and Gas) power bus.

5
Engine-generator units 1 and 2 were each instrumented to measure generated electrical power. The main power bus was instrumented to measure

total generated electrical power, power factor, frequency, and line

voltage. Power consumption measurements were made on the following

branches: plant lighting, three motor control centers (MCC1, MCC2

,

MCC3), PTC exhauster, normal power bus at each building, essential power

bus at each building. Power bus line voltages were monitored at each

site building and at the local utility's input feeder. The PTC system

contained two exhausters driven by 150 HP motors, a hydraulic trash com- pactor and a series of control valves. A continuously operating exhaust

fan prevented unpleasant odors from acculmulating in the system. The

large exhausters, which represent over 90% of the PTC load, were instrumented for electrical power consumption.

2.7 SITE BUILDING MEASUREMENTS

The buildings on the site received all electrical, cooling and heating

services from the central total energy plant. These buildings consisted

of four apartment buildings, a commercial building, an elementary school

and a swimming pool

.

Measurements were made in each building to determine thermal energy used

from the secondary hot water loop for space heating, thermal energy used

to produce domestic hot water, thermal energy added to the secondary

chilled water system, electrical power consumed on normal and essential

electrical busses, and normal line voltage. Figure 15 shows the measurements made in a typical building.

Some buildings deviated slightly from this plan, for example, the pool

was not air conditioned and therefore did not use chilled water. From

measurements made at each building a determination could be made of

building energy demands and of the losses in the secondary distribution

systems

.

Schematic diagrams of transducer locations and their respective NBS code

numbers for the site hot water and chilled water distribution systems are included in appendices 1 and 2.

3. INSTRUMENTS USED AT THE TOTAL ENERGY SITE

The instruments installed at the total energy site measured the following

parameters: electrical power, voltage, water and fuel oil flow rates,

actual and differential temperatures, exhaust gas pressure, lubrication

oil pressure, water pressure, engine-generator malfunctions, barometric

pressure, solar radiation, wind velocity and wind direction. The transducers and their associated signal conditioning circuits are described

in this section.

3.1 ELECTRICAL INSTRUMENTATION

Twenty-three electrical power and eleven voltage measurements were made

at the site. Of these thirty-four measurements, thirteen were in the
power plant and twenty-one were in remote buildings. Additional instruments installed in the engine control room in the CEB and independent of

the DAS included a kilowatt-hour meter registering the total produced

power and strip charts recording frequency, power and line voltage

levels

.

3.1.1 Voltage

Power bus voltage levels were measured by converting the AC line voltage

to a DC level. The 480 VAC line voltage was stepped down by a 4:1 potential transformer to 120 VAC. (The 120 VAC range was compatible with

circuit component ratings and a safety factor was gained by being isolated from the 480 volt line through the potential transformer). A fullwave rectifier circuit and R-C filtering converted the 120 VAC signal to

a DC analog level which was recorded by the DAS.

3.1.2 Electrical Power

Electrical power measurements were performed by Hall-effect watttransducers. These devices were connected to electrical busses thru

potential and current transformers which provided input signal levels

compatible with the semiconductor transducers.

The Hall-effect transducer multiplied the instantaneous voltage and

instantaneous current signals from the potential and current transformers

performing the computation V«I«C0S 0 = P (watts). The transducer analog

DC output was electronically integrated to produce integrated power

(kilowatt-hour) data. Integration of the transducer output from kilowatts

to kilowatt-hours was accomplished by a pulse-counting scheme as shown

in Figure 16. A voltage-to-f requency (V-F) converter generated pulses

at a rate proportional to the Hall transducer output voltage. These

pulses were summarized by a 12 stage digital counter. The binary output

of the counter was fed to an 8 bit digital-to-analog converter (DAC)

whose output varied from 0 to +5.00 volts DC. This output voltage was sampled and recorded by the DAS. The maximum output voltage of +5.00

volts DC corresponded to 8192 counts. The next pulse (above 8192) reset

the output voltage to zero.

In order to maintain the total pulse count between data scans to less

than 8192, a dividing (scaling) circuit was inserted at the input to the

counter which divided the input pulses by powers of two (2^). N could

be set to any value from 0 to 9 by a thumbwheel switch mounted on the

integration printed circuit card.

A line diagram of a typical power bus instrumented for voltage and kilowatt hour measurements is shown in Figure 17.

The power measurement system and integrating circuits were designed and

built at the NBS.

7
3.2 FLUID FLOW INSTRUMENTATION

Water flow measurements for primary hot water, chilled water, secondary

hot and chilled water and cooling tower water were obtained through

venturi tubes, differential pressure transducers and nutating disk

meters. Two totalizing nutating disk flow meters registered the fuel

consumed by the engines and by the entire plant and provided back-up

data if the turbines or DAS malfunctioned. Differential pressures from

thirty-one venturi tubes, two nutating disk flow meters and seven turbines were monitored by the DAS.

High water flow rates were measured by venturi tubes with differential

pressure cells. Low flow rates were measured by nutating disk flowmeters. The thirty one venturi tubes were installed in water pipes which

varied from one to ten inches in diameter, and sensed flow rates from 300

to 20,000 pounds per minute. Nutating disk flowmeters measured secondary

hot-water flow in the school and commercial building.

The flow rate through a venturi is measured by sensing the pressure drop

in the venturi's throat due to the increased velocity of the flow in the

throat. The pressure drop is given by:

where V is the flow velocity in the throat, p is the fluid density, g is

the gravitation constant, and A

2 /A

j

is the ratio of the pipe area to the

throat area. A differential pressure cell measures this pressure drop.

A typical piping arrangement and installation of a venturi and differential pressure cell are shown in Figures 18 and 19. The pressure cell is

mounted below the venturi to prevent static errors occurring from air

collecting in the lines. A typical venturi is shown in Figure 20; the

wire handles are connected to cleanout rods used to clear the

venturi's pressure pick-off anulus.

The differential pressure cell is a solid-state device consisting of a bellows that displaces a strain gauge connected to a bridge and amplifier

circuit. The device generates a 4 to 20 milliampere signal current which

corresponds to the minimum and maximum differential pressures, respectively. The signal current flows through a precision 500 ohm resistor

and produces a signal voltage that varies from +2.0 to +10.0 volts DC.

This voltage level is directly proportional to differential pressure in

inches of water. The differential pressure transducers used at the site

had a range from 0 to 150 inches of water.

The venturis were selected to produce a differential pressure of approximately 150 inches of water at the maximum anticipated flow rates. Each

venturi was delivered with an individual calibration chart and these data

are incorporated in the computer's data processing routines. Typical

venturi are included in appendix 4.

8
The differential pressure cells were periodically recalibrated at the

site. The venturi clean-out rods were periodically plunged to prevent

sediment from plugging the venturi's pressure ports (see Figure 21).

To minimize the possibility of fouling of the pressure cells, the cell

lines were periodically opened to drain any collected sediment.

The nutating disk flowmeters were equipped with a reed relay that provides contact closures, as the fluid flows through the meter. The contact closures, which correspond to unit volume of flow, were sensed by an electronic circuit that generates a pulse for each closure. The

pulses were totalized by a digital to analog converter into an analog

voltage which was sampled by the DAS. A nutating disk meter is relatively immune to fouling.

3.2.2 Fuel Flow

Seven turbine meters were used to measure individual fuel consumption of

the five engines and two boilers. These turbines (see Figure 22) were

capable of accurate measurement for flow rates as low as 0.1 gallons per

minute. Figure 23 shows the locations of the fuel measuring instruments.

The turbines were installed upstream of the injector racks on the engines

and upstream of the firing nozzles on the boilers, (see Figure 24 and

25). A three valve arrangement for each engine turbine allowed fuel to

be by-passed around the turbine permitting removal of the turbine without

disturbing the operation of the engine. No bypass was provided on the

boiler turbines since depressurization of the fuel line and replacement

of the turbine required a simple boiler shut down of less than five minutes duration.

The turbine output was a 10 to 100 millivolt peak-to-peak sinusoidal

signal developed by a magnetic pickoff. As shown in Figure 26, this signal was amplified, shaped, divided (if necessary) and counted (totalized)

in a 10 stage counter. The binary coded decimal output of the counter fed

the digital-to-analog converter. The analog DC voltage output of the DAC was sampled and recorded by the DAS.

Each turbine was delivered with 10 point calibration tables for test runs conducted with #2 fuel oil at 68°F and 86°F. The calibrations were

checked and confirmed at NBS. The individual turbine calibration data

were incorporated in the NBS computer software which processed the data

received from the site.

3 . 3 Temperature Instrumentation

There were 54 thermocouples measuring actual temperatures and 42 thermopiles measuring differential temperatures on the Jersey City total

energy system. All but five of the temperature measurements were made

by Type T, copper-constantan, thermocouples and thermopiles. Type J,

iron-constantan, thermocouples were used to measure engine exhaust stack

and boiler exhaust stack temperatures.

9
For water temperature measurements, the thermocouples were potted and

mounted in stainless steel wells as shown in Figures 27 and 28.

Differential temperatures were sensed by multiple pairs of copperconstantan thermocouples combined into thermopiles. The higher signal

level generated by the thermopile provided greater temperature resolution by the data acquisition system (DAS).

Each thermopile had one thermocouple junction which was used with an icepoint reference junction to measure the actual thermopile temperature

which is needed to compute the differential temperature from the thermopile voltage. The thermocouples, thermopiles and thermowells were fabricated and calibrated by NBS in accordance with ASTM practices.

Thermocouples require reference temperature junctions to measure actual

temperatures. The CEB and each building on the site was equipped with

an ice-point temperature reference unit. These units thermoelectrically

cool very pure water to the point that ice begins to form, producing the

desired reference temperature.

3.4 ALARM SENSORS AND INSTRUMENTATION

Because the reliability of the engine-generators was of particular importance in the analysis of the Jersey City Total Energy system, the ability

to identify and record specific malfunctions that caused an enginegenerator to shut down or flash alarm signals was incorporated into the

instrumentation.

Twelve functions were monitored by the plant control system for each

engine-generator to indicate whether electrical, mechanical and thermal

systems were within normal limits, a total of 60 malfunction signals for

all five engine generations. Each monitor has only two output levels, a low level when conditions were normal and a high level when conditions

were out of limits. To reduce the number of DAS channels from 60 to 10

channels, a digital weighting scheme was designed (see Figure 29).

Groups of six alarm signal lines were connected to a digital-to-analog

converter (DAC). Each discrete output level from the digital-to-analog

converter represented a unique combination of on and off states of the

six inputs.

The following alarms and malfunctions were instrumented on each enginegenerator.

10
Engine Generator

low oil pressure

high oil temperature

high oil coolant temperature

high jacket water temperature

overspeed

underspeed

excessive start time

excessive vibration

circuit breaker trip

overload

failure to parallel

reverse power protection

Difficulty was encountered in recording the malfunction signals because

of peculiarities in the engine control system wiring. These problems are discussed in Section 10.5.

3.5 WEATHER INSTRUMENTATION

Seven weather measurements were made at the site: air temperature,

humidity, barometric pressure, wind direction, wind speed, direct solar

insolation, and indirect solar insolation. Two of these measurements

(dry bulb temperature, humidity) are made in an instrument shelter box

located on the roof of the Descon building (see Figure 30). A small

exhaust fan continuously circulates outside air through the box. Air

temperature is measured by a thermistor and bridge circuit and a hygroscopic hair-type element coupled to a potentiometer measured relative

humidity. Two pyranometers were located on the roof of the elevator

shaft penthouse (Descon building) and measure direct solar insolation

and indirect insolation. These instruments are constructed with thermopiles that are placed under black and white areas of an exposed disc.

The signal from the thermopile is directly proportional to the radiant

energy striking the disk. The direct (Figure 31) and diffuse units differ in that the diffuse unit was shaded from the direct radiation from

the sun by a shadow band (see Figure 32). The shadow band was adjusted

each week to compensate for the seasonally changing declination angle of

the sun.

An aerovane measured wind velocity and wind direction. The instrument

was mounted, on a thirty foot tower on the roof of the Camci building.

(See figures 33 and 34). Camci was chosen for the aerovane location

because it is the tallest building on the site and is equipped with a lightning protection grid. Signals from the aerovane are sent to the

central DAS through Camci' s remote DAS station.

4. DATA ACQUISITION SYSTEM

4.1 SITE REQUIREMENTS

The features of the DAS were designed to provide the data needs for a TE

system performance analysis as discussed in section 2.0 and to be adaptable to the physical site configurations. The number of measurements

required for the performance analysis was over 200. Due to the site

layout, measurements had to be made at widely separated points over a
6.3 acre area with instruments located from 15 feet below ground level

to heights of 17 stories. Data recording had to be in a format suitable

to rapid reduction and system operation had to require a minimum of

operator attendance.

A digital computer performed the data reduction and analysis tasks to

accomplish timely processing of site data. Since all sensors at the site

were analog devices, the question arose as to where to make the signal

conversion into digital form. The digital conversion could be accom- plished anywhere in the signal transmission chain, from transducer to

tape recorder. If the conversion was made at the transducer, the

sensor was considered to be a digital device and interconnecting cables

had to be capable of carrying digital information. If a digital sensor

signal is transmitted over a single signal pair of wires then the digital data has to flow in a serial fashion and the time required to sample

200 points could be several minutes. If the sensor data are transmitted

in parallel form, the sampling speed increases significantly, however the

requirement for additional signal lines increases by a factor of six

because each sensor requires at least six signal lines (to transmit a 5.00 volt signal in binary code with an accuracy of 1.6% requires six

lines). Six lines will resolve the signal into 63 parts, therefore the

smallest signal increment is: 5.00 volts/63 = .079 volts or 1.58% of

the maximum value). If the analog to digital conversion was made at a point where the signal transmission path became common to all sensor

signals then an optimum balance could be achieved between data sampling

speed, minimum signal cable requirements and less complex wire routing.

The decision was made in favor of locating an optimum point where the

digital conversion could take place. This optimum point was the common

signal path at the input to the scanner controller. The scanner

controller directed all the analog signals to the DVM where they were digitized. The signal flow diagram in section 4.2 shows the convergence

of sensor signals to the scannner controller unit.

4.2 DAS DESCRIPTION AND DATA SAMPLING RATIONALE

The function of the data acquisition system was to sample 223 analog signals generated throughout the total energy complex, digitize the analog

signals and record them in digital code on magnetic tape. A data scan was initiated every five minutes and required 30 seconds to sample and

record all the signals generated at the site.

The factors that lead to a 30 second recording speed are discussed in

section 5.3, "DAS Scanning Speed". The following factors established

the five minute sampling interval. To determine the optimum time interval between data scans, a study was made of the variations in water flow

rates and temperature in the primary hot water loop, electrical power

demand and fuel consumption. Water flow rates varied less than 2%

within any 60 minute interval. Water temperature changes were gradual

in any 15 minute period. Fuel consumption rates did not exhibit any

abrupt changes in any one hour period. Total electrical power demand

increased during the morning hours (6 a.m. to 8 a.m.) and evening hours

(4 p.m. to 7 p.m.). These load variations were gradual over any 30
minute period. Of the 23 electrical branch loads that were instrumented

for power consumption data, the pneumatic trash collection (PTC) system

was the only cyclic load that required an appreciable amount of electrical power for very short periods of time. The PTC required 125 kilowatts

of power and operates for five minutes in each hour. Selecting a five

minute DAS sampling rate would identify a PTC system malfunction to

within 5 minutes and consequently other system malfunctions would be nar- rowed to a five minute interval. The feasibility of establishing a five

minute scan interval was governed by the magnetic tape capacity and the

data tape service schedule established at the site. A ten-inch reel car- rying 2400 feet of magnetic tape could record 282 channels of data every

5 minutes for 19 days (see section 6.8). A nineteen day capacity was compatible with a data tape collection schedule which anticipated a change of tape reels every week.

The data acquisition system consisted of a central DAS located in the

central equipment building (figures 35, 36, 37) and eight remote DAS

stations (figures 38 and 39). A remote station was located in each of

the seven site buildings, the eighth station was installed on the roof

of the Descon building to service the weather station instruments.

Each remote station could monitor data from fourteen sensors, for a total of 112 remote data channels. The central DAS was built by Monitor

Labs of San Diego, California to specifications provided by NBS (see

appendix 3). The signal processing and conditioning circuits used in

the remote stations and in the central equipment building were designed

and fabricated at the NBS.

Signals from the transducers located in the central equipment building

(170 local data channels) were connected directly to the central DAS by

shielded cables. Transducer signals generated at the weather station

and at site buildings were sent to the remote stations where they were conditioned and then transmitted to the central station. To minimize

the complexity of installing a separate pair of signal wires from each

of the 112 remote points to the central DAS, a multiplexing scheme of

data channel selection was used. One signal line was connected between

the central station and each remote station. The central station

selected a remote data channel, recorded the data on magnetic tape, then

disconnected the channel and proceeded to select the next data channel.

In this manner the fourteen signals at each remote station could be ser- viced, one at a time, over a common line. The DAS channel selection

sequence started with the remote stations and recorded data from all the

remote channels. Then the sequence moved to the CEB and the remainder

of the data channels interrogated and their signal levels recorded on magnetic tape. The following figure is a simplified diagram indicating

signal flow from transducer to tape recorder. The DAS scanned a total

of 282 channels including 223 active data channels and 59 spare channels.

13
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4.3 DAS CAPABILITIES AND DATA HANDLING

The data acquisition system at Jersey City had the capability to monitor

and record data from 170 channels in the central equipment building and

14 channels from each one of ten remote stations. In the final configuration the Jersey City site was using 8 remote stations with 2 stations

available for future expansion. Each remote station is expandable to

30 channels and the central station is expandable to 1000 channels.

Signals were transmitted, interference free, from remote stations to the

central station for distances up to 700 feet (section 6.3 discusses signal transmission). The channel interrogation rate or scanning speed could

be varied and was set at 9.4 channels per second. This scan rate was of

sufficient speed, relative to the rate of change of the total energy

parameters, to insure that each scan cycle is essentially an instantaneous moment for all the data channels. The 223 transducers installed

throughout the plant and site buildings translated physical and electrical variables into analog voltage signals that were conditioned (i.e.

amplified, scaled to uniform voltage levels, converted into pulses),

digitized and recorded on the DAS magnetic tape recorder.

The parameters measured were:

Flow Rates

Fuel oil flow rate

Water flow rate

Temperatures

Water

Fuel oil

Outside air

Electrical Characteristics

Power

Frequency

Power Factor

Voltage

Weather Characteristics

Solar Radiation

Humidity

Wind Velocity

Wind Direction

The only expedient approach to reducing the large quantities of raw data

accumulated at the site was through computer data processing. The initial plan for this total energy site analysis provided for a digital com- puter to perform the system analysis. The data on the magnetic tape was

15
computer compatible and could be reduced and processed by standard software routines.

When the nine-track magnetic tape reel in the DAS had accumulated data

for about a week, the reel was removed and sent to the NBS for data

reduction on a Raytheon 704 digital computer. Data processing involved

converting the signal voltage levels recorded on the magnetic tape into

engineering units (kilowatts, gallons per minute, degrees Fahrenheit)

and then transferring the enginering units, channel identification and

the original voltage levels to a new seven track magnetic tape. The nine

track DAS tape was placed in storage and the seven track tape supplied

the data input to the computer for additional processing. The transfer

of data from nine track tape to a digital computer was essentially an automatic operation after the operator has selected the proper software

routine through the Cathode Ray Tube (CRT) keyboard and initiated a start

command. There were provisions for operator and computer interaction

during the data processing phase and these are discussed in section 7.2.

5. SYSTEM OPERATION

The data acquisition system operated in a full automatic, single scan mode initiated by a system start pulse generated by the DAS digital

clock. Thirty seconds of data were recorded on magnetic tape at fiveminute intervals. When the tape recorder was inactive, data could be

transmitted over telephone lines to the NBS. The system was unattended

requiring only occasional service and periodic change of magnetic tape

reels. This period could be as long as nineteen days though NBS has

found it expedient to remove and process a data tape each week. Section

5.8 discusses maximum recording capacity in full detail.

5.1 INPUTS

The central station digital voltmeter (DVM) would accept DC analog voltages ranging from + 00.000 millivolts to + 150.00 volts. Meter resolution was one microvolt on the millivolt range and one millivolt on the

ten volt range. Input signals ranged from low millivolt to ten volt

levels and were a function of the transducer and signal conditioning

circuits. Thermocouples generated (on an average) a 15 millivolt signal,

differential thermocouple signals were in the 10 to 24 millivolt range.

Electrical power and turbine flow measurements were processed through

digital to analog converters that produced a 0 to +10 volt signal. A

differential pressure transmitter sensing venturi flow generated a +2.000

to +10.000 volt signal. Selection of the appropriate DVM range to suit

the level of the incoming signal was an automatic feature of the DVM and

is covered in greater detail in section 6.6.

5.2 OUTPUTS

Three data recording devices were serviced by the DAS, a magnetic tape

recorder, a modem (modulator/demodulator) link and a printer. The DAS

could send data to only one device at a time, therefore, if all three

recording devices were selected (at the DAS coupler panel) to receive

16
data, the DAS would service the devices sequentially in the following

order; tape recorder (one complete scan), modem (one complete scan),

printer (one complete scan). Under normal operating procedures only

the tape recorder and modem were selected. The printer was used when an operator desired printed data while performing a system calibration or output data check.

5.2.1 Magnetic Tape Recorder

The magnetic tape recorder was an incremental nine-track unit and was

the primary data logging device. System timing pulses, scanning speeds

and data update intervals were selected to utilize the high recording

speed capability of the tape recorder. At the beginning of each fiveminute interval the signal level from each transducer was recorded on magnetic tape. This was a 30 second operation (9.4 channels per second)

and for the remaining four and a half minutes channel data were transmitted at a slower speed (approximately 168 seconds per scan) over the

modem link.

5.2.2 Modem

When the tape recorder was inactive, the modem link was energized and

DAS data transmitted over telephone lines to a Raytheon model 704 minicomputer at the NBS in Gaithersburg, Maryland. Transmitting one full scan of data took 2.8 minutes. The modem was a Vadic model VA300 with

a maximum data tramsmission rate of 30 characters per second. The digital computer decoded the modem transmission, converted the data into

engineering units and could display the characters on a cathode ray tube

or store the data in computer memory for transfer to magnetic tape. The

modem was a back-up for the tape recorder and provided an indication of

site performance and a daily verification, at the National Bureau of

Standards, that the DAS was functioning.

5.2.3 Printer

A Centronix model 301 impact printer was located at the site and provided

a hard copy output of data channel information (figure 42). The hard

copy printout could be examined at the site to determine whether all

data channels are operating properly. The data coupler formatted the

output information to put label and time information on a separate line

and then group channels, five to a line. A typical printer scan time for

the 282 channels was four minutes. A sample of printer hard copy output

is shown in figure 43.

5.3 DAS SCANNING SPEED

As shown in the DAS signal timing chart below, a transducer analog signal

was routed and processed through: the remote slave scanner, CEB slave

scanner, scanner controller, digital voltmeter, data coupler and tape

recorder. All of the devices had an effect on the system scanning speed

and as the following analysis indicates, the digital voltmeter was the

device that set a limit on the maximum scanning speed.
DAS

SIGNAL

TIMING

CHART

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Time

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170

local

channels
The remote scanner took five milliseconds to sequence through a remote

channel and also introduced a 200 millisecond delay between each remote

station. The CEB slave scanner and scanner controller required five

milliseconds to sequence through a channel. The digital voltmeter

required from 41 to 58 milliseconds to digitize an analog signal with

the average conversion time being 50 milliseconds. The 50 millisecond

average is covered in greater detail in section 6.6, (Digital Voltmeter).

The data coupler's delay was only one millisecond due its data buffering

feature which is explained in section 6.7 (Data Coupler). When the DVM

transferred data to the coupler the data was placed into a storage

buffer, then the coupler signalled the DVM and the scanner controller

to read the next channel and proceed to output the data from the storage

buffer to the tape recorder in 17.3 milliseconds. The tape recorder then

waited from 38.3 milliseconds to 60.7 milliseconds for data to arrive

from the next channel. The time required to transfer data from the

coupler to the tape recorder was not assessed against scanning time

because the data transfer occurred while the DAS was processing the next

channel. Tape recorder characteristics and recording speed are covered

in section 6.8.

Determining DAS Scanning Speed :

Time required to scan all the remote channels.

5 milliseconds per channel X 112 channels = .516 s 200 millisecond delay X 8 stations = 1.6 s 2.116 s

Average time to scan through a remote data

channel. 112 channels

2.116 s 19 ms per channel

Time to sample and record one remote data channel

19 ms + 5 ms + 50 ms + 1 ms 75 ms

remote CEB

scan + scan + DVM + coupler

Time to sample and record one local channel (CEB)

5 ms + 50 ms + 1 ms = 56 ms

CEB

scan + DVM + coupler

19
Time for total scan.

112 remote channels X 75 ms

170 local channels X 56 ms 8.4 s 9.52 s 17.92 s

Maximum DAS scanning speed

282 channels 15.7 channels per second

17.92 s With the DAS scan time adjusted to 30 seconds, the scanning speed of 9.4

channels per second (282/30) was well within the systems speed limit.

It was also apparent that the DVM was the slowest device in the signal

procesing chain and had the greatest effect on the system scanning speed.

5.4 OPERATIONAL MODES

The data acquisition system could be operated in three modes: single

scan, continuous scan and monitor mode. The operational mode was selected at the scanner controller panel, (figure 44), by pressing the

appropriate push button switches.

5.4.1 Single Scan

Single scan caused a single interrogation of all system channels and

would record the beginning time of scan and the data from each channel

when output was to the printer and tape. Selecting the modem output

automatically enabled the continuous mode feature where the DAS would,

at the end of each scan, reset the first channel and restart a scan until a manual stop or reset button is pushed. A slight departure from

this occurred when both tape and modem are enabled, which was the normal

operating mode of the DAS. A start pulse would start a scan and data

were output to tape only. At the completion of the tape scan the scanner reset and the DAS entered the continuous mode with modem output enabled.

The DAS would then scan in continuous mode with modem only output until

the controller received another start pulse. A start pulse would always

reset and restart the scanner, enabling tape output for the first scan

only, and then change to modem. This allowed single tape scans to be

written at regular time intervals, with the modem available continuously

the rest of the time. System start pulses could be initiated by a time

pulse from the digital clock or manually by an operator pushing the con- troller start button.

5.4.2 Continuous Mode

Continuous mode will cause the DAS to scan from the first channel to the

last channel selected at the scanner control panel, (figure 42), and

will continue to be repeated until the cause of the continuous mode is

removed or until operator intervention.

20
Continuous mode is enabled automatically when modem output is selected.

The continuous mode with tape only output would be utilized in an instance where recorded data is desired at shorter time intervals than

the normal automatic clock interval.

5.4.3 Monitor Mode

In this mode the system continuously monitored one selected channel and

continuously updated the display of the digital voltmeter and the channel

stored display in the system controller unit. This mode was not used

for output purposes. When appropriate buttons were depressed on the

system controller panel, the DVM would read the voltage value on the

channel selected by the scanner controller first point thumbwheel setting. The DVM update frequency was operator controlled and adjustable

from one to four times a second. Monitor mode was used for observing

a particular channel over a brief period of time.

6. MAJOR SYSTEM COMPONENTS

A central station located in the CEB, eight remote stations located in

seven site buildings and the remote signal cables comprised the data

acquisition system. The central station contained seven separate chassis

mounted in a single rack. They were: the system digital clock, digital

voltmeter (DVM), scanner controller, system controller, data coupler,

slave scanner and a 9 track digital tape recorder (Figures 35, 36, 37).

A remote station consisted of a remote scanner slave chassis, signal

processing circuitry and signal terminal strips (Figures 38, 39). The

signal and control cables from the remote stations and signal cables

from the CEB transducers terminated in wall mounted junction boxes in

the DAS room. Multipair shielded cables connected the terminal boxes to

the scanner slave chassis.

6.1 DIGITAL CLOCK

The system digital clock, incorporating an accurate crystal time base,

generated the correct day of the year and time of day. A digital readout

displayed the day and time in hours, minutes and seconds. Recordable

digital output data was sent to the coupler unit to be output to the

system recording devices with each data scan record. The clock also

issued a system start pulse to the scanner controller unit at a time

interval that was selected by front panel controls (Figure 45). The

interval between start pulses could be adjusted from 1 second to 9 days

and was set to 5 minutes for the total energy site. The system start

pulse was generated continuously and would initiate data scans at 5 minute intervals until an operator turned the start pulse switch to the

off position. The clock was equipped with a continuously on-charge NICAD

battery circuit that supplied power to the chassis in case of power

failure. The battery would run the clock circuits for three hours to

insure that clock accuracy was maintained through a power interruption.

Clock adjustments, to accomodate daylight saving time, was made manually

during a data tape exchange. The time correction was entered into the

computer for all subsequent data tapes.

21
6.2 SLAVE SCANNER

Analog signals from the total energy transducers entered the data acquisition system at the slave scanner through relay contacts. The CEB

slave scanner contained seventeen multiplexing printed circuit (PC) cards

and logic circuitry to operate the relays. Each PC card contained 10

relays, one for each individual data channel. Thirteen command lines,

from the system controller, selectively energized the relays in the slave

unit. The input signals were connected to the DVM through the relay

contacts. All analog data signals at the site were carried through

shielded signal wire pairs.

Although relays cannot achieve the multiplexing speeds possible with

transistor switching, they were chosen over solid state switches because

they have very low resistance through closed contacts and low thermal

offsets. The relays used for multiplexing had thermal offsets of less

than one microvolt at 68°F (20° C) and contact resistances of less than

0.05 ohms. These specifications could not be met by solid state switches.

Low thermal offsets and low contact resistance were necessary to successfully switch low level thermocouple signals in the millivolt range (where

20 microvolts represents one degree F) without signal degradation. The

relays had a maximum switching speed of 200 channels per second which

imposed no limitations on the 9 channels per second operational requirement. Figure 46 is a schematic of a 10 relay printed circuit card.

6.3 REMOTE SLAVE SCANNER

A remote slave scanner was located at each remote station and contained:

a power supply, a 10 channel relay multiplexing card, a four-channel

multiplexing relay card, a scaling card to attenuate signals greater

than 10 millivolts, and an operational-amplifier (op-amp) adjusted to

a voltage gain of 1000. The plugin relay assembly was identical to the one described in the slave scanner section 6.2. All remote signals are amplified and then transmitted to the central station.

There were considerable advantages in using an op-amp when analog signals were transmitted over relatively long distances, up to 700 feet between

the remote station and the central recording station. Non-amplif ied low

level signals (in the microvolt and millivolt range) transmitted in noisy

environments would have been subject to being obscured by noise induced

in the signal lines (a low signal to noise ratio situation).

The noise interference problem was brought under control by transmitting

all analog signals at high levels, 1 to 10 volts, taking advantage of the

very low output impedance (0.1 ohm) of the op-amps and using shielded

signal wires. The op-amp low output impedance was conducive to reducing

signal line noise pickup.

Transducer signal levels at the remote stations ranged from 1 millivolt

to 5 volts. Levels that were below 10 millivolts were connected directly

to the op-amp input. Signal levels above 10 millivolts were connected to

a scaling card (that contained resistor attenuating networks) and reduced

22
to levels not to exceed 10 millivolts. A record of the scaling factors

for each attenuated signal was part of the mini-computer processing program.

6.4 SCANNER CONTROLLER

The scanner controller determined which channels were to be scanned by

establishing the first and last channel to be scanned. The setting of

thumbwheels labeled "first point" and "last point" controlled the channels

that were to be interrogated (Figure 44). Upon receipt of a start pulse,

from the front panel run switch or from the system clock, the scanner

controller would select data channels in numerical sequence starting at

the "first point" channel and ending at the "last point" channel. The

current channel selected was displayed on a digital readout. The system

scanning speed was selected by the delay control and was adjustable from

fifteen channels per second to one channel per second.

Selecting a channel was the process of connecting an analog voltage from

a transducer to the digital voltmeter input terminals through relay contacts. The relays were located in the slave scanner chassis and the

scanner controller closed the relay for the channel being interrogated.

CEB transducers were connected directly to slave scanner relays on channels 010 to 179 (local channels). Remote slave scanners which selected

and transmitted remote analog signals were accessed by channels 000

through 009. When a remote channel was selected the scanner controller

activated the system controller which then sequenced the fourteen remote

sub-channels. This control is evident in the schematic showing the DAS

control signals and data flow, figure 41.

The scanner controller could operate in a single, continuous or monitor

mode by selecting the appropriate front panel controls. These operational modes were described in Section 5.4.

6.5 SYSTEM CONTROLLER

The system controller interfaced functions of the DAS components by coor- dinating the timing of system pulses, commands and by controlling the

transfer of data from the DVM and clock to the data coupler. It also

controlled remote station multiplexing. A normal scan started with a start pulse from the digital clock which was routed through the system

controller to the scanner controller where the "first point" channel was loaded and to the data coupler where an "enable" command was generated

and sent to the magnetic tape recorder. The controller issued a pulse

to the digital voltmeter commanding it to read the voltage signal at its

input terminals. The signal was then encoded into binary coded decimal

(BCD) form and transferred to the data coupler. The system controller

then incremented the channels in the scanner controller by issuing a channel "advance pulse". For remote multiplexing, subchannel "first

point" and "last point" thumbwheels, located on the controller front

panel, determined the subchannels to be scanned. The normal setting was

first point 00, last point 13. Beyond channel 010 only the scanner con- trollers sequencing circuits were involved. The system controller also
provided a means of selecting and displaying, on a five character front

panel display, the voltage signal level for any channel. The channel

was selected by thumbwheel switches labeled "channel stored". The display labeled "stored reading", figure 37, was updated each time the

selected channel was scanned.

6.6 DIGITAL VOLTMETER

The digital voltmeter (DVM) converted the analog signals at its input

terminals into a binary coded decimal (BCD) output signal. The DVM was a DANA Labs model 4800 five digit instrument. BCD data output was delivered

on 18 lines; four lines for each of the four least significant digits

(weighted 1, 2, 4, 8) and two lines for the most significant digit

(weighted 1, 2). The meter measurement capabilities included DC volts,

ohms, AC volts and voltage ratios. When incorporated in the DAS the DVM

was wired to function only in the DC volts mode. The DVM had five voltage ranges; 10 millivolts, 0.1 volts, 1 volt, 10 volts, 150 volts. An

autoranging feature automatically selected the best voltage range for

a given input signal. An analog signal was digitized in 41 milliseconds,

with the autoranging feature the time could be as long as 58.4 milliseconds. The increased time was due to the voltage comparison being made

between the input signal level and the five voltage ranges. Maximum con- version time occured when a signal in the 10 mV range was followed by

a signal in the 100 volt range. The minimum 41 ms conversion time (read

time) occurred when succeeding signals are in the same voltage range.

In order to minimize the DVM conversion time, transducer signals were

grouped into blocks of ten where signal levels were all in the same voltage range. This block grouping resulted in an average conversion

time (for 232 channels) of 50 milliseconds.

6.7 DATA COUPLER

The data coupler transferred binary coded decimal (BCD) data from the

DVM to a maximum of three recording devices (tape recorder, modem,

printer). The DVM data was placed into a storage buffer within the

coupler and then the system controller and DVM were signaled to advance

and read the next channel. While the DVM was digitizing the signal level

in the next channel, the stored data was transferred to the recording

device. This technique of overlapping functions produced faster scanning

speeds. In the process of data transfer, the data was arranged into word

groups and encoded for the recording device used. When interfacing with

the magnetic tape recorder the data were encoded into Extended Binary

Coded Decimal Interface Code (EBCDIC) format and a character transferred

to the tape recorder in parallel 8 bit words. Data to the modem link

and printer were encoded in American Standard Code for Information

Exchange (ASCII) format and transferred in a serial bit stream. Pushbutton controls on the front panel wereused to select the desired

recording devices. In addition to the data handling operation the coupler inserted time, data and label information to the recording devices

at the beginning of each data scan. Label information consisted of a group of 12 numbers that were manually selected by thumbwheel switches

located on the front panel. The thumbwheels were set by an operator each
time a new tape reel was loaded. The numbers were selected to indicate

the date and time the new reel was mounted and served as an identification number for each tape reel.

The data coupler could operate in a standby, automatic or single mode by

selecting the appropriate pushbuttons on the front panel (see figure 47

for front panel controls). In the standby mode the coupler would issue

all interface control signals but would not record data. This allowed

system checks without unwanted recordings. In the single mode the DAS

performed one scan and recording when the manual start button is pressed.

In the automatic mode, which is the position for recording site data, a DAS scan was initiated by an external start command from the digital

clock and data was recorded for each scan.

6.8 DIGITAL TAPE RECORDER

The DAS digital magnetic tape recorder was a Kennedy model 1610 incremental nine track write-only unit with provisions to record longitudinal and

vertical parity bits for detection of erroneously recorded data (figure

48). In incremental recording each data character was written upon command. The tape transport advanced one increment upon command from the

data coupler then stopped and waited for the next step command. The size

of the step depended on the packing density (recording density) specification for the tape unit; the model 1610 density is 800 bytes per inch

(bpi) , therefore each step took up 0.0012 inches of tape. The data was evenly spaced on the tape regardless of the frequency of the data source

provided the maximum stepping rate, 750 bytes per second (bps), of the

recorder was not exceeded. At the maximum recording rate a byte (which

represents one complete character) was recorded in 1.33 milliseconds.

Data for a single channel (containing 13 characters) was recorded in

17.33 milliseconds. Figure 49 illustrates the data output format to

the tape recorder. Tape capacity was 2400 feet of 1/2 inch, 1.5 mil

computer tape mounted on a 10 1/2 inch reel. The length of time that

the DAS could operate unattended could be determined by calculating the

amount of data that could be deposited on a reel of tape with a data

scan occurring every 5 minutes. The following calculations indicate that

a reel of tape could store 19 days of data.

Number of characters in one complete scan of 282 channels:

282 channels X 13 characters = 3666 characters

plus

label and time recorded

at the beginning of =12+7 =19 characters

each scan.

= 3685 characters

3685 characters = 4.6 inches of tape

800 bytes per inch

plus

25
a 0.6 inch interrecord

gap (IRG) added to

the end of each scan. = 0.6 inches of tape

= 5.2 inches of tape

Tape length per day.

12 (scans per hour) X 24 (hours) X 5.2 (inches) = 1498 inches per day

Full reel recording capacity:

Full reel of tape = 2400 X 12 inches = 19.2 days

Daily Usage 1498 inches per day

7. DATA PROCESSING

7.1 OUTPUT FORMAT

The DAS data output format was identical for all 3 output devices, see section 49. The first characters output during a scan were the 12 data

coupler thumbwheel digits, the label data. Seven digits of the clock

time data containing day of year and hour and minute of the day were

output next, followed by channel numbers and voltage magnitude going from

the scanner first point (of the first channel) through to the last point

(of the last channel). The data coupler caused the tape unit to write an interrecord gap after the last point data was written. For printer output the coupler sent a carriage return and blank characters to arrange

the hard copy characters into an easily readable form.

Figure 49 shows a layout of the DAS output format. Each DVM reading was output in a 13 character group containing 3 digits of the scanner channel

number, 2 digit subchannel or 2 blanks, a one digit DVM function code, a plus or a minus sign for voltage polarity, five digits of data, and a one digit DVM range-code. One data record on tape contained 3685 characters.

7.2 DATA EDITING AND CONVERSION

All computer processing of raw data was performed on a Raytheon 704 minicomputer. The computer had 32K of memory with seven- and nine-track tape

drives, two disk drives, CRT terminal with a hard copy machine and a high

speed paper tape punch and reader. All data processing programs were resident in the system library on disk and could be loaded and executed

by operator commands to the system monitor.

The time base for processed data output was a one hour period. For each

data channel twelve five minute scan values were combined to yield a single data point representing the hour. Further processing yielded daily

and monthly values for each measured variable. In addition, so called

"derived variables" were calculated. These quantities were gallons of

fuel consumed, kilowatt hours of electrical energy produced and consumed,

and the heat (in Btu) produced or used in the TE system. A Btu calculation involved multiplying a water flow value by a delta temperature value

26
for hourly data values. All one hour, dally and monthly values for data

channel variables and derived variables were stored on a monthly disk.

Data points on disk could be displayed in a table form or on a X-Y plot

display on the CRT, and hard copy printed.

Data processing routines were set up to read a scan and convert voltage

readings to engineering units, automatically proceeding from scan to scan. The computer software would automatically handle data tape errors

such as illegal characters, spurious interrecord gaps (IRG's) written

before the last point channel is reached, and parity errors without

interrupting the data processing routines.

Once editing routines had checked the raw data in a single scan for correct format and characters, and any needed corrections had been made,

calculations could be performed that converted the analog voltage readings back to physical quantities. The software used the channel number

written preceding the data to identify the appropriate conversion equation. For example, channel 050 was a type T thermocouple measuring primary hot water temperature to the engines. The equation T°C = Am^ +

Bm^ + Cm^ + Dm, where m is the millivolt measurement and A thru D are constants, was used for channel 050 and all type T thermocouple measurements. Another typical conversion was the signal from a differential

pressure cell placed across a flow venturi. Channel 015 monitors the

main PHW venturi. Pressure drop measured by the cell was described by

P = k (m - 2000) where m is the millivolt signal. The differential

pressure was then used in the venturi flow equation F = A * B • y V2gP

where A and B are constants unique to each individual venturi, and y is

the specific weight of the water which was calculated separately using

the temperature measurement of channel 050, and g is the gravitational

constant

.

8. DAS AND INSTRUMENTATION COSTS

An accounting of the cost to implement the data collection system used

to evaluate the performance of the JCTE site is presented in this section. All elements of the effort are reported in terms of dollars.

Cost figures were derived from 3 sources; estimation of NBS in-house

manpower, contracts awarded outside of NBS, and equipment purchases.

NBS in-house manpower costs were assessed by accumulating the amount of

time spent by NBS personnel in the various activity areas, and multiplying by the appropriate salary received plus overhead.

Contracts to private firms were awarded for work done at the Jersey

City site. Most equipment installation was performed by the on-site

mechanical and electrical building; contractors, under fixed price

contracts. All site contractors used union labor. In most cases,

building construction and installation of instrumentation were performed

concurrently. Items making up a contractor’s bid typically included

labor, overhead and profit, and material not specifically supplied by

the NBS. The amounts and descriptions of individual installation contracts are reported as cost items.

27
Amounts reported for equipment purchases from outside vendors are purchase prices of the DAS, transducers and discrete hardware elements.

For hardware fabricated by NBS personnel, an estimated cost is given on labor and material expenses.

In order to reflect the composition of the total cost of implementing

the JCTE instrumentation system, 3 major areas are defined. These areas

are: system design (including equipment selection), equipment purchase

and installation, and system checkout.

8.1 INSTRUMENTATION DESIGN COSTS

The design of the instrumentation system involved NBS manpower resources

in several activities. Some time was devoted to familiarization with the

Jersey City Total Energy plant and site design, and all pertinent documentation. Once data needs were defined the designation of transducer

locations, and the selection of transducers among different types and

manufacturers was performed. NBS worked with the DAS contractor to

determine the optimum DAS configuration. Preparation of documentation

of all instrumentation and DAS details was the final step before installation activities began. Design activities began in 1970 and continued

through early 1973. The total expenditure for NBS in-house manpower

devoted to instrumentation system design is estimated to be $516K.

8.2 EQUIPMENT PURCHASE AND INSTALLATION COSTS

The two major hardware areas are the DAS, and the instrumentation. The

DAS is the data logger that sequentially selects signals from the CEB

and remote building transducers and records digitized voltage values on magnetic tape. The instrumentation includes all mechanical and electrical transducers, any power source that provides electrical excitation for

transducers, coupling cable between two or more transducers, any signal

conditioning circuitry such as watt-hour integrating circuits, and signal cable from a transducer to the terminal strip where the signal

voltage may be selected on a DAS data channel. Instrumentation costs are reported by measurement type.

8.2.1 DAS Cost

The purchase of the DAS was based on competitve bids submitted by vendors

responding to technical requirements detailed in a DAS specification

written by NBS. The monitoring of signals from the remote buildings, up

to 700 feet from the CEB, made special demands on the capabilities of a data logging system. Monitor Labs of San Diego, California was awarded

the contract to design and build a DAS for $50,000 in 1972. The hardware

supplied included the chassis of the central station located in the CEB,

namely, the clock, scanner, DVM, controller, tape drive and scanner

slave. It also included eight remote stations, each consisting of multiplexing circuitry and an operational amplifier. Detailed documentation

of all circuitry and cabling, and operational handbooks were also furnished by Monitor Labs.

28
8.2.2 Flow Instrumentation Costs

Water flow measurements on the TE site of greater than 200 lb/min utilize

a venturi and differential pressure (A.p.) cell. NBS purchased all 31

venturi tubes with calibration curves from 2 vendors in 1972. The price

of a venturi is generally dependent on the nominal pipe diameter and measuring capacity. For example, the purchase price for a venturi placed in

a 3-inch pipe to meter a nominal 400 lb/min was $900, including calibration curves and constants derived from precision calibration tests. The

largest venturi, 10-inch ID., metering 18,000 lb/min cost $2124. The

average original cost for all 31 venturis with calibrations was $1275.

Thirty one (31) differential pressure cells were purchased from ITT

Barton of Industry, Ca. , and were $566 each. The 5 pressure cells that

monitor engine oil pressure, exhaust stack pressure and primary hot water

system pressure, also, from ITT Barton, cost $520 each.

The 4 nutating disk meters that measured water and oil flow from 40 to

150 lb/min were purchased in 1976 at a cost of $260 each. Two meters

measure fuel flow into the CEB day tanks, (manually read) and two are used for domestic hot water measurement in the school and Business Building. Approximately 15% additional was expended for repair parts.

The seven turbine meters used to meter 5 engine fuel flows and 2 boiler

fuel flows were purchased with calibration information for $620 each in

1976.

Each flow sensor monitored by the DAS required an electronic interface

that produced an electrical signal for the DAS. The CEB and the 7 remote

site buildings each required one electronic power supply for differential

pressure cells. The high amperage CEB supply cost $171. The smaller

capacity building supplies cost $91. All were purchased in 1973. Turbines and nutating disk meters fed signal conditioning and integrating

circuitry that was designed and fabricated by NBS. An estimated per

data channel cost for electronics for 7 fuel turbines and 2 nutating

disk meters is $250.

Mechanical installation of differential pressure cells consisted of

mounting the cells and connecting each of two venturi ports to the cell

inlets with 3/4 inch copper tubing, using 5 gate valves per cell. In

the CEB, the contractor that constructed the building mechanical system

installed NBS venturis and thermowells. Later, a separate firm installed

20 d.p. and pressure cells, not including electrical wiring, for a fixed

price bid of $20,000. In the remote buildings, installation of NBS supplied venturis, d.p. cells, and thermowells, was performed under a single

contract. In the remote buildings, the average cost for mechanical

installation of 3 venturis, 3 d.p. cells, and 6 thermowells, was $5500

and was performed by the original building contractor in all cases.

The seven turbine meters on five engines and two boilers were installed

by the CEB diesel engine service contractor for $2450. All four nutating

disk meters were installed by NBS, at a total estimated cost of $1,000.

29
8.2.3 Temperature Measurement Costs

Hardware required for temperature measurements included: multipair thermopiles fabricated by NBS from thermocouple cable, 3/4 inch I.D. stainless steel wells and fittings, one electronic ice point reference for

each site building, terminal strips, junction boxes, conduit and cable

trough. NBS supplied all thermopiles and thermocouple cable to contractors. About 1250 feet of 16 pair thermocouple cable was used to fabricate

83, 16 pair thermopiles. Another 2250 feet of the cable were used to

connect piles together for delta temperature measurements. The price for

3500 feet of this cable in 1973 was $2,000. 90 thermowells with fittings

(7 were spares) were fabricated by the NBS shops at a cost of $50 per

well. The 100 channel ice-point reference for all CEB temperature measurements cost $1890. Each of the seven ice-point references for remote

buildings cost $685. Installation of temperature instrumentation is discussed in the next section.

8.2.4 Electrical Measurement Costs

Basic hardware required for measurement of electrical system parameters

includes current transformers (CTs) and potential transformers (PTs),

Hall-effect watt transducers, integrating circuitry for watt-hour measurements, and wire leads run in conduit from transformers to signal

conditioning circuitry. Twenty watt transducers were supplied by NBS

for all site power masurements at a cost of $180 each. Signal conditioning circuitry for all electrical signals was designed and fabricated at NBS, at an estimated per channel cost of $250.

All electrical installation on the site was performed by private con- struction contractors. Site electrical contractors installed all

electrical transducers as well as wiring for flow and temperature transducers. In a remote building typical work included: purchase and

installation on main power busses of 4 PTs and 4 CTs, wiring of PTs and

CTs to a switch box and then to the NBS supplied remote cabinet, installation and wiring of six, 16-pair thermopiles, installation of an ice

point reference, wiring of 3 d.p. cells, and termination of a 15-pair

DAS multiplexing cable in the NBS remote cabinet. All cables were supplied by NBS and were run in conduit by the contractor. The contractor

supplied all materials except thermopiles and cable. Work in the four

residential buildings was similar in scope and cost. The average price

for the electrical installation contracts in each of the seven site

buildings was $7,200.

The main electrical installation contract for the CEB differed somewhat

in scope from the remote building contracts. CTs and PTs had already

been installed by the original building contractor. The secondary con- tractor made their connections to NBS electronics. Twenty pressure cells

and 47, 16-pair thermopiles were wired and all signal cables run to the

DAS terminal boxes. Approximately 1000 external DAS wire connections

were made in the DAS room. Contractor-supplied material included all

junction boxes, conduit for all cable runs, and all terminal strips and

30
special copper and constantan metal terminal lugs. The electrical

contract for CEB instrumentation and DAS installation was awarded by

HUD for $71,800.

8.2.5 Weather Station Costs

Weather station instrumentation costs for hardware totaled $3,268 for a wind speed and direction aerovane, aerovane tower, temperature and humidity sensors, two solar radiation sensors and signal conditioning electronics. Installation costs for mounting of the tower and connecting it

to the building lightning protection system were $3,450.

8.2.6 NBS Manpower Costs

Very little actual installation of equipment was performed by NBS personnel. The use of NBS manpower resources was necessitated by the strict

specifications for instrumentation installation at the JCTE site. Constant communication with the non-technically oriented construction contractors was essential to assure correct installation of transducers,

and dealing promptly with field changes in order not to compromise

measurement location or accuracy. Costs attributable to site installation activities are man hours for trips to Jersey City during site construction and travel expenses. Transportation and per diem expenses for

a Monday through Friday trip in 1973 were approximately $200 per person,

not including salary earned while in transit. Another NBS in-house activity that contributed to hardware installation costs was operational

check out of new equipment received at NBS, before it was transported

to the site. In most cases this involved the efforts of engineers and

technicians who verified the correct operation of differential pressure

cells, thermocouples, watt transducers and conditioning circuitry, and

weather station sensors.

NBS installation activities were conducted from the time of ground

breaking at the site in 1972 until completion of the last remote building

electrical contract in early 1976. The total cost of NBS instrumentation

installation activities is estimated to be $226K.

8.3 NBS CHECK OUT COSTS

Data system check out involved verifying that the installed instrumentation and DAS could perform the desired measurement and recording functions correctly. Some typical field activities were: field calibration

of thermocouples and thermopiles using DAS voltage readouts, initial d.p.

cell calibration, verification of correct remote building slave scanner

multiplexing, comparison of manually-probed electrical power rates to DAS

automated measurements, performing preliminary energy balance calculations and computer reading of raw data tape output to verify correct

operation of the tape drive and data coupler.

The total cost of NBS field check out activities is estimated to be

$200K.

31
EQUIPMENT COST TABULATION

DAS HARDWARE (Monitor Labs, San Diego, CA)

Chassis in central station rack - clock, DVM controller, scanner,

tape drive, slave scanner

Remote station hardware consisting of multiplexing circuits and

relays and operational amplifier. Eight remote stations supplied.

Fixed price contract, all hardware $50,000.00

VENTURI FLOW MEASUREMENTS

HARDWARE

Venturis (Vickery Sims, Arlington, TX, and Badger Meter, Milwaukee,

WI) with calibration information, 33 purchased for the TE site, 1972

Smallest, 3" ID = $900

Largest, 10" ID = $2,124

Average price = $1275 x 33 42,075.00

Differential Pressure Cell(ITT Barton, Industry, CA), one each per

venturi, 34 purchased in 1972

Unit price $566 19,244.00

Power supply (Lambda, Melville, NY) for d.p. cell transmitters, 1 required in CEB, 1 each required in 7 remote buildings

CEB unit price 171.00

Remote Unit price $91 637.00

Electrical cable, NBS supplied, for wiring from DAS to d.p. cell

Cable, for TE site 200.00

Calibration pressure isolators, 2 each required per d.p. cell, 62

used on TE site Design and development cost 4,000.00

Fabrication cost, per unit $20 1,240.00

INSTALLATION

CEB mechanical installation of 20 d.p. cells. Mount and connect

d.p. cells, contractor supplies all piping material and valves.

Fixed price contractor with private

contracting firm. $19,000.00

Remote building mechanical installation - for each building install

3 venturis in water lines, mount and install 3 d.p. cells, install

6 thermowells. 7 separate site building installations contracted.

Average price, each building

$5,500. 38,500.00

TOTAL FOR ALL SITE VENTURI FLOW

MEASUREMENTS, HARDWARE AND

INSTALLATION $125,067.00

32
ELECTRICAL MEASUREMENTS

Watt transducers (Bell Inc, Columbus, OH) - purchased by NBS , 23

used for all CEB and site building measurements.

Unit price $200. $ 4,600.00

Signal conditioning circuitry - designed and fabricated by NBS

Estimated per channel cost $150. 2,300.00

CEB Electrical Installation - install and wire 47 thermopiles, wire

20 pressure cells, install 3 watt transducer chassis, install DAS,

install and wire ice point reference, wire turbine meters, supply

all conduit and junction boxes

Fixed price contract 71,800.00

Remote Building Electrical Installation - contractor supplies and

installs PTs , CTs , switch panel, wires d.p. cells, supplies all PT

and CT wires, conduits, junction boxes, installs and wires thermopiles

Average price for each of

6 remote buildings $7,200 43,200.00

$121,900.00

WEATHER STATION MEASUREMENTS

Hardware (Bendix Corp., Baltimore, MD) - Purchased by NBS in 1973,

aerovane, temperature and humidity sensors, electronics, and aerovane tower (Rohn, Peoria, IL)

Total, weather hardware 1,588.00

Solar sensors (Eppley Laboratory, Newport, RI) - one direct, one indirect Total for solar sensors 1,680.00

Installation - Mount tower, route extra cable, tie in to lightning

protection grid Fixed price contract 3,450.00

WEATHER STATION TOTAL $6,718.00

NUTATING DISK METERS (Badger Meter, Milwaukee, WI)

Meter - 4 each purchased by NBS for 2 domestic hot water measurements and 2 fuel oil measurements

Unit price $260 X 4 $1,040.00

Installation - performed by NBS. Estimated total cost 1 , 000.00

TOTAL, HARDWARE AND INSTALLATION 2,040.00

0MNIFL0 TURBINES (Flow Technology Inc, Phoenix, AZ)

Meter - 7 purchased by NBS for fuel measurements, with calibration

information Unit price $620 X 7 $4,340.00

33
Installation - on 5 engines and boilers performed by the CEB diesel

service contractor. Wiring by NBS

Fixed price contract $2,450.00

Signal conditioning electronics - designed and fabricated by NBS

Estimated total cost for

7 measurements 1,750.00

ITT Barton Turbines (Monterey Park, CA)

15 turbines. Total cost $8 , 800.00

Total for Turbine Measurements,

Hardware and Installation 17,340.00

TEMPERATURE MEASUREMENTS

Thermopiles - 83 used on TE site. Cable used for pile fabrication

purchased by NBS in 1972.

Total cost $ 710.00

Thermopile Fabrication - 16 junctions welded per pile by NBS

Estimated cost, 83 thermopiles 2,000.00

Thermowells and fittings - one well per thermocouple plus 7 spares,

fabricated at NBS shop. Unit price $50 x 90 4,500.00

Ice point references (Kaye Instruments, Cambridge, MA) - purchased

by NBS, 1972 100 channel unit for CEB 1,700.00

6 channel unit, 7 required for

remote buildings. Unit price $685 4,795.00

Connection and signal cable - for connections between thermopiles,

and for signals to DAS and ice point references

All cable for TE site 1,800.00

$15,505.00

GRAND TOTAL $338,570.00

34
9. SENSOR SELECTION AND ACCURACIES

The accuracy goals for field measurements were 1% or better at the sensor

output plus 1% or less degradation for signal conditioning and processing

yielding a recorded accuracy of 2%. Signal conditioning refers to signal

attenuation, amplification and wave shape changes. Signal processing

applies to signal integration, multiplication, voltage to frequency (V/F)

and frequency to voltage (F/V) conversions.

Flow Measurements

The choice of instruments for fluid flow measurements were venturis, turbines, nutating disk meters and target type meters. With the exception

of the venturi, the signal generating components of the flow meters were

in the fluid stream and in the event of an instrument failure the flow

had to be stopped or by-passed around the meter to remove the defective

instrument, whereas the venturi is a relatively simple (though precise)

pipe section with small ports drilled in the casting to permit pressure

measurements

.

The water distribution pipes at the Jersey City site varied from 3" to

12" in diameter with flow rates from 170 gpm to 2500 gpm. The addition

of by-pass plumbing and valving for the large water pipes would have

created plumbing line clearance problems and increased contractor installation costs. Venturies were available with calibration curves assuring

0.5% accuracies and their use would obviate the need for by-pass plumbing, therefore, the venturi was considered the best device for measuring

the high flow rates in the primary, secondary and chilled water loops.

The parameter that was measured in the venturi was differential pressure

(AP) and the flow rate was calculated by the computer by inserting the

value of A P into the venturi flow equation. The AP across the venturi

was measured by a transducer that provided a DC signal proportional

to theAP. Manufacturer’s stated accuracy for the pressure transducer

(A p cell) was 0.5% and repeatability was 0.2%. The AP cells were

periodically calibrated in the field to 1% accuracy. Venturi signals

originating in the CEB were carried directly to the DVM and digitized.

The DVM could contribute a maximum 0.1% error in the conversion process.

The signal path from the DVM to the tape recorder was simply data transfer and did not affect the signal magnitude.

AP cell signals generated at the remote buildings had a stage of signal conditioning added between the transducer and the DVM. The signal

was attenuated in a resistive divider network and amplified by an operational - amplifier (this signal path is evident in the drawing in sec- tion 4.2). The op-amp gain accuracy was 0.01% and was field calibrated

to 0.1%. Amplifier errors due to the zero shifting with time and with

temperature changes were cancelled out during the data processing phase.

Every remote station provided a channel with a shorted input to the

op-amp. The signal level recorded for this channel was applied as a correction factor during the data reduction phase.

35
Considering a worst case condition, the accuracy of a venturi pressure

measurement from the CEB to the tape recorder was 1.0% (transducer) +

0.1% (DVM) = 1.1% and from a remote building was 1.0% (transducer) + 0.1%

(DVM) + 0.1% (conditioning circuits) = 1.2%.

The initital measurement system determined fuel consumption by measuring

the difference in fuel oil flow between the supply and return lines that

connect the fuel day tanks to the engines and boilers. Figure 23 illustrates the fuel flow path and location of the turbine meters in each day

tank fuel line. Though the turbine specifications indicated a 0.1% accuracy and a 0.02% repeatability, considerable error was experienced in the

fuel measurement. A new metering system capable of measuring consumed

fuel directly was substituted for the original flow-difference measuring

technique. The present measuring system uses a turbine in each engine's

fuel injection line and a turbine in each boiler nozzle. A discussion of

the fuel measurement problems and their solution is included in section

10.3.

Fuel flow rates, going directly into an engine or boiler, ranged from 0.4

to 1.5 gpm and the turbine was the only sensor that offered a 0.5% accuracy in the lower than 1.5 gpm range with a repeatability of 0.1%. The

turbine meter was also an attractive choice because it produces a sinus idal signal suitable for electronic conditioning. The fuel parameter of

interest was not the flow rate but the fuel consumed. The turbine is a volumetric device that indicates the number of volume units (counts) that

pass through the turbine. The computer had to multiply the total counts

by a coefficient (K factor) to yield gallons consumed. The turbine signal was processed through a F/V converter that totalized (integrated) the

transducer signal (figure 26) and produced a DC level proportional to the

volume of fuel consumed. The accuracy of the consumed fuel measurement

with a 1.0% factory calibration was:

1.0% (turbine) + 0.1% (F/V) + 0.1% (DVM) = 1.2%

In order to provide a long term accumulative total of fuel use, two

nutating disk meters were installed in the day tank refill lines. Each

meter was equipped with a mechanical register that totalized to 10 million gallons. These meters were calibrated at the NBS to a 1.5% accuracy.

Turbines were initially installed in the business building and school to

measure water flow in the 20 gpm range. The turbine rotors became

encrusted with mineral deposits carried by the water. Filters were added

to combat this problem but they would clog up after two weeks of service, so nutating disk meters were substituted for the turbines. The

nutating disk meters were not as demanding of filtered and particle free

fluids. They were equipped with relay contacts to adapt them to automatic data logging systems. Each meter had a 1.5% accuracy over its operating range. Meter contact closures were sensed and the signal processed

by a circuit that is identical to the F/V unit described above for turbine fuel measurements.

36
The disk meter is also a volumetric device and the processed signal

represented the volume of water passed through the meter. The accuracy of the water volume measurement was:

1.5% (disk meter) + 0.1% (F/V) + 0.1% (remote op-amp)

+ 0.1% (DVM) = 1.8%

Electrical Power Measurements

Since the parameter of interest, in the electric system was kilowatthour (kW-hr) consumption, the selection of a transducer focused on a device that would measure power (watts) and lend itself to a straightforward approach to computing (electronically) kilowatt hours. A class

of power measuring transducers that had recently become available was the

Hall-effect type. This transducer produced a DC voltage that was proportional to the measured AC power. The DC voltage would be processed to

represent kW-hrs and recorded by a data logging system. The Hall-effect

electrical power transducer had a manufacturer’s specified accuracy of

0.5%. The transducers were calibrated in the field (after installation)

to 1.0%. All power measurements were made with Hall-effect transducers.

The output signal was processed into a kilowatt-hour signal (see figure

16) and recorded on tape. The processing circuits consisted of a V/F

converter accurate to 1 count out of 500 or 0.12%, and a digital to analog converter (F/V) consisting of 256 steps for a 5 volt maximum output

signal. The maximum uncertainty the DAS could encounter when sampling

this output voltage was one step or .4% (5/256 = 20 millivolts out of 5 volts). The accuracy of a kilowatt-hour measurement made in the CEB was:

1.0% (transducer) + 0.2% (V/F) + 0.4% (F/V) + 0.1% (DVM) = 1.7%

and in a remote building:

1.0% (transducer) + 0.2% (V/F) + 0.4% (F/V) + 0.1% (op-amp) +

0.1% (DVM) = 1.8%

The electrical power measurement in several remote buildings exceeds the

1.8% error due to line loading conditions that are discussed in section

10 . 1 .

Temperature Measurements

Ninety-six points were designated for temperature measurements at the

total energy site. Fifty-five measurements were actual temperatures and

forty-one differential temperatures. Since a large quantity of temperature sensors had to be assembled, the thermocouple sensor was chosen for

its simplicity, ruggedness and ease of fabrication. The problem of low

signal levels, encountered when measuring small differential temperatures

was met by constructing 10-pair thermopiles which increased the signal

level by a factor of ten. The non-linearity of the thermocouple elements

(90% were type T, copper - constantan, 10% were type J, iron - constantan) posed no problem since the DAS recorded only the potential level of

the thermocouple and the computer calculated the corresponding temperature. The accuracy of the temperature measurement was a function of the

37
homogeneity of the metal wire, the accuracy of the reference junction,

the terminal junction at the meter and the properties of the medium in

which the sensor is immersed. The American Standard for Temperature

Measurement Thermocouples (C96.1 - 1964) lists the special limits of

error for type T, copper - constantan, in the - 70°F to 200°F range

at + 0.75°F. Thermocouple manufacturers consider this table of "limit of

error” to be a practical maximum.

The total maximum error for a thermocouple measurement would be 1.5°F;

0.75°F at the measurement junction and ,75°F at the reference junction.

This maximum error applied to a PHW measurement at 180°F and a chilled

water measurment at 45°F would represent 0.8% and 3.5% errors respectively. The maximum error in recorded value would be:

PHW = 0 ,8%( thermocouple) + 0.01%(ref erence temp.) + 0.1% (op-amp) +

0 . 1 % ( DVM ) = 1.01%

Chilled Water = 3. 5%( thermocouple) + .01%(ref. temp.) +

0. l%(op-amp) + 0.1% (DVM) = 3.75

%

Each thermocouple data channel was calibrated at the site (after installation) by immersing the thermocouple into 33°F and 80°F liquids. The

liquid temperature was measured by a thermometer certified to a 0.2°F

accuracy. The thermocouple voltage levels were recorded from the digitizing voltmeter in the DAS. The final voltage reading included all terminal connection and wire length affects. Every thermocouple channel

correlated to within 1.0% of the reference thermometer.

Another factor that has an effect on the accuracy is the temperature

probe location. The thermocouples were inserted in stainless steel walls

that protrude into the water stream. Since the thermocouple was not in

direct contact with the water the thermal conductivity of the steel well

and the silicon rubber that insulates the tip of the thermocouple enter

into the temperature measurement. The time constant effect of the different materials between the thermocouple and the water was not explored.

However, the characteristics of the circulating water loops at the total

energy site were such that the temperature of the water loops was not

subject to abrupt change and the flow-rates could be considered constant.

Possible errors introduced by the well configuration, well material or heat conduction from thermocouple to well wall was not explored.

Weather Station

The weather station components were manufactured by Bendix-Friez Co. and

were furnished with the following manufacturer's stated operational accu- racies :

Barometric Pressure : An aneroid barometer device measuring 27 to 31

inches of mercury to an accuracy of 0.5% of reading.

Data channel accuracy = 0.5% (transducer) + 0.1% (op-amp) + 0.1% (DVM) = 0.7%

38
Air Temperature: Thermister probe. Accurate to 1.5% of reading from

-20 U F to +12CTF.

Data channel accuracy = 1.5% (probe) + 0.1% (op-amp) + 0.1% (DVM) = 1.7%

Humidity : Accuracy is 3.0% of reading from 30% to 70% RH.

Data channel accuracy = 3.0% (transducer) + 0.1% (op-amp) + 0.1% (DVM) = 3.2%

Solar Radiation : Accuracy is 3.0% of reading. Range from 0 to 2.0 cal/

cm^ min.

Data channel accuracy = 3.0% (transducer) + 0.1% (op-amp) + 0.1% (DVM) = 3.2%.

Wind Velocity : Aerovane accuracy is 2.0% of reading from 0 to 100 mph.

Data channel accuracy = 2.0% (aerovane) + 0.1% (op-amp) + 0.1% (DVM) =

2 . 2 %

Wind Direction : Aerovane accuracy is 2.0% of reading from 0 to 360

degrees.

Data channel accuracy = 2.0% (aerovane) + 0.1% (op-amp) + 0.1% (DVM) =

2 . 2 %

10. INSTRUMENATION PROBLEMS

10.1 ELECTRICAL MEASUREMENTS

Several problems were encountered in electrical measurements. Complicated wiring schemes and inaccesible locations for the potential transformers, current transformers and the main power transducer, made the

calibration and servicing of the electrical measurement system a difficult task. As a result of the wiring method, it was very difficult

to service the NBS electrical power transducer which measured total generated power. The plant design specified a single set of current transformers on the main power bus to feed the engine control system

transducer, the NBS gross power transducer, the plant total power kilowatt-hour meter and the plant strip-chart recorder. As a consequence,

all of these devices were connected in a series fashion to the main

current transformers so that maintenance on any one of these four devices

affected the functioning of the other devices. The transducers could be

switched out of the system for calibration or service and our experience

when replacing an original power transducer without shutting down the

entire plant required awareness that transducer servicing with "hot"

power busses is a delicate and potentially hazardous procedure. The

original power distribution design should have incorporated shorting

switches across each measuring device to facilitate the safe and easy

removal of malfunctioning instruments. For further safety and flexibility, each transducer should be serviced by a separate set of current

and potential transformers. Whenever possible, when maintenance is to

be performed on any of these four devices it should be scheduled to

coincide with an electrical plant shut down.

39
Several current transformers, used with the power transducers to measure

building electrical loads, were changed to units with lower turn ratios.

The original CT's were chosen on the basis of early building load estimates. These estimates proved to be too high. The new current transformers were installed during scheduled building power shutdowns.

Problems were encountered in the analysis of building electrical loads.

A comparison of the electrical power delivered by the CEB to the remote

buildings with the summation of each building's power consumption varied

from 1.0% to 15.0%. A detailed thorough inspection of the actual building

wiring and load distribution systems revealed that the power distribution

system differed in each building. Normally, the electrical power loads

on the essential power bus would be; elevators, fire pumps, stairwell

lights and fire alarms. The remaining electrical services would be on the normal power bus. The Shelley A building had one elevator on the

essential bus and the other elevator on the normal power bus. The same condition existed at the Descon building. The single elevator in the

business building is powered by the normal bus. These situations are a result of different electrical contractors working on each building. The

electrical wiring in the Camci building was installed by two independent

contractors. The substantial deviation of electrical loading from early

estimates had an impact on the power measurement system. The watt transducers originally chosen for the building power measurements were two

element devices which monitor the current in two lines of a three phase

circuit. This instrumentation is accurate for a constant potential and

balanced load condition. The constant potential condition is maintained

at the buildings at all times. However, load unbalances of 30% were occurring for several hours during the day. Wherever feasible, three

element watt transducers were installed. In the Shelley A, Descon and

Camci buildings, the addition of a third current transformer (to accom- modate a three element transducer) was not feasible since access to the

primary feeder bus would have required the disassembling of a power

distribution cabinet and would have required a building power shutdown

for several days.

In a total energy environment, it is desirable to separate the gross

electrical power generated to two parts (1) the electrical power used in

generating the power, commonly known as parasitic load; and (2) the electrical power that would have been purchased from the public utilities

if the plant were not generating its own electrical power. With the

existing motor control center wiring at the Jersey City Total Energy

Site, the loads parasitic to the generation of electrical power could

not be directly measured. In most cases, local electrical codes and

regulations made it necessary for the contractor to feed both parasitic

generation loads and HVAC loads from the same motor control center. For

example, the motor control center which received essential power, MCC-1,

supplied most of the parasitic generation loads to facilitate restarting

the plant in the event of an outage, however, codes required the boilers

to be placed on this same motor control center. Secondary hot water

pumps, and house pumps were also supplied by this same motor control

center thereby mixing the HVAC and parasitic electrical generation loads.

40
A major redesign would be required to separate the motor control centers

to allow direct measurement of the parasitic loads. The cost of the

necessary changes was judged not compatible with the measurement objectives. Instead, these loads were determined indirectly by the computer.

The computer program examines thermal data to assess the on/off state of

individual plant HVAC equipment and predicted the cumulative hours of

individual operation. The electrical power demand of the equipment

(determined from voltage and current measurements made at the equipment)

was multipled by hours of operation to determine the kilowatt-hours consumed by plant HVAC equipment. Parasitic electrical loads were determined from the difference between the total motor control center demand

and the HVAC demand.

Similar problems have been encountered in allocating the plant electrical

air compressor loads between the electrical plant controls and the pneumatic trash collection system (PTC). One system supplied compressed air

for the diesel engine starters, for some engine controls and for the PTC

controls. Due to large line leak losses in the PTC control system the

allocation of the compressor electrical power between the operation of

the electrical plant and PTC was difficult. Fortunately, the electrical

loads of the two air compressors with 15 horsepower motors were small

relative to the continuous parasitic loads of the primary hot water loop

circulating pumps and the intermittent loads of the 150 HP motor of the

PTC exhausters. These loads made the exact allocation of the compressor

loads insignificant.

10.2 WATER FLOW MEASUREMENTS

Measurement problems were encountered in the differential pressure (Ap)

cell systems (monitoring the primary hot water flow) within a month of

initial installation. Foreign particles collected in the bellows of the

Ap cell causing the instrument to offset to a maximum reading or affecting the linearity of the instrument. Figure 50 is a photograph of a debris laden bellow assembly.

The problem of foreign material building up in the folds of the bellows

was relieved by installing bleed lines on both sides of all differential

pressure cells as shown in Figures 18 and 19. The bleed lines were

installed so that sediment collecting in the pressure lines could be

flushed by opening the bleed valves and allowing the water flowing

through the venturi to flush out the lines and the annular rings in the

venturi. Flow rates that exceeded the range of the Ap cells occured in

the secondary hot water (SHW) lines in Camci and Shelley A buildings

after the first year of operation. The cause was traced to a building

action. The original 450 gpm hot water pumps failed and were replaced

by larger 750 gpm units. To accommodate the higher flow rates, pressure

transducers with larger dynamic ranges replaced the original units.

Problems were encountered in the two instances (school and business

building) where turbines were originally installed to measure flow to

the domestic heat exchangers. Sediment in the water clogged the turbines. Filters were installed to remove the sediment and particles

41
upstream from the turbines. However, the filters became clogged after a few days of service. As a final solution, a nutating disk flow meter,

a type of meter more tolerant to unfiltered liquids, was substituted

for the turbines.

To insure the integrity of the Ap cell measurement an in situ calibration

procedure was realized through the design of an interface device (items B in figure 19). The interface device transfers an externally applied differential air pressure through an isolating diaphram to the water filled

Ap cell. The differential air pressure is varied over the design range

of the cell and the signal output level is recorded to assure that the

cell is maintaining a 1.0% accuracy. The calibration procedure requires

the closing of the venturi line valves and connecting the air pressure

source. After calibration the venturi line valves are opened and the

air source is disconnected. A calibration is performed each month.

Figure 52 is a photograph of the portable test unit used to calibrate the

Ap cells.

10.3 FUEL OIL FLOW MEASUREMENTS

The only systems consuming fuel oil at the TE site were the diesel engine

system (five engines) and hot water boiler system (two boilers). These

systems are commonly designed to draw their fuel from a constantly circulating fuel supply, therefore each system at the site had a fuel supply

line and a fuel return line (figure 23). Approximately 15.0 gallons of

fuel per minute flowed through the engines' supply line and 13.5 gallons

per minute (gpm) flowed through the return line, the difference being

the fuel used by the diesel engines. The boiler fuel system operated

with a fuel flow rate in the 12 gpm region. In the initial measurement

system, turbine meters were used to measure the total supply and return

rates to the engines and boilers. The engine and boiler fuel consumptions were then calculated by the computer by subtracting the return flow

rate from the supply flow rate. When the fuel consumption calculations,

derived from the recorded data, were compared against fuel delivery

invoices discrepencies of 15% appeared, which required resolution.

Arrangements were made to return the turbines to the manufacturer for a recalibration. In order for the fuel measurement system to yield a 1.0%

accuracy, using a supply and return scheme, the turbine meters must be

capable of calibration to an accuracy of 0.1% or better. An average of

1.5 gpm of fuel are consumed when three diesel engines are in operation.

With a 15 gpm flow in the supply line the return line would carry a 13.5 gpm flow rate. Assuming a one percent error in the supply turbine

(the measurement would indicate 15.15 gpm) and no error in the return

turbine, the consumed fuel calculation would be: 15.15 gpm (supply) -

13.5

gpm (return) = 1.65 gpm. This is a 10% error over the actual 1.5

gpm. A 0.1% error in the supply turbine measurement would reflect a 1.0% error in the calculated fuel consumption; 15.015 gpm (supply) -

13.5

gpm (return) = 1.515 gpm, 1.515 gpm - 1.5 gpm = 1.0%. The required

1.5

gpm (actual)

measurement accuracy was within the operational capability of all the

supply and return turbines used at the total energy site. It took the

42
manufacturer several months to complete the calibrations. In the meantime

NBS explored the feasibility of metering the fuel as it went directly

into the Diesel engine cylinders and into the boilers. A metering point

was identified in the engine fuel injection system and new turbine meters

(from a second manufacturer) designed to measure flow rates in the 0.1

to 1.0 gpm range, were purchased and installed in each diesel engine.

Technical discussions with the boiler manufacturer indicated that a direct

fuel measurement could be made in the line supplying fuel to the boiler

nozzle. New turbines rated from 0.2 to 2.0 gpm were installed in the

boilers. As a further check on the fuel feed system, nutating disk

meters with totalizing mechanical registers were installed in the two

CEB day tank fuel lines figure 51 (one tank supplied the engines, the

other tank supplied the boilers). These were 1000-gallon tanks that

were frequently topped with approximately 12 gallons of fuel every seven

minutes. When the recalibrated total supply and return turbine meters

were returned from the manufacturer and reinstalled, and the fuel

measurement data examined, discrepancies of 10% were still present so the turbines were taken to the NBS and calibrated at the fluid mechanics

laboratory. The NBS "K" factors (the calibration factor "K" = pulses per

gallon) were 8 to 14% higher than those submitted by the manufacturer.

Using the NBS calibration the supply and return method of fuel measurement agreed with the day tank measurement to within 2.0%. Though the

engine fuel consumption is determined from the direct engine measurement,

the performance investigation of the return and supply method was pursued

to verify that this method can yield accurate measurements since many

fuel supply systems are accessible only at the supply and return lines.

The factor that was clearly demonstrated by this exercise in fuel measurement was that when instrument calibration demands enter the fraction

of one percent region, it is necessary to use calibration equipment and

procedures capable of this accuracy.

10.4 TEMPERATURE MEASUREMENTS

During the data checkout phase of the temperature measuring system

examined variations were noted in the differential temperature measurement (PHW) across engines one and two. These variations were greater

than expected when compared against the total engine bank differential

temperature.

The two temperature variations were traced to cooling effects at the top

of two thermowells caused by cold ventilation air blowing directly across

the thermowells. The thermocouple wells for engines 1 and 2 are directly

under a chilled air grating. Subsequent examination of the data showed

that the variations in T, which could be caused by the cooling air was

2°F. This represented a 15% error during the periods when ventilating

fans were in operation. The effects of the ventilating air was com- pletely eliminated by improving the thermal insulation on engine 1 and 2

thermocouples (figure 27). As a consequence of identifying this localized temperature measurement error, NBS insulated or reinsulated every

thermowell in the site to determine if any other temperature anomalies

existed. An analysis of site thermal data for January 1976 to September

1976 (insulation was installed in S tember 1976) and October 1976
through September 1977 indicated that the additional insulation applied

to the CEB thermowells had no effect on the temperature measurements.

Of the 54 actual and 42 differential thermocouple temperature measurements, two T measurments were found to be in error due to an immediatearea environmental influence.

10.5 ENGINE-GENERATOR ALARM INSTRUMENTATION

The engine-generator alarm instrumentation was not fully utilized in data

monitoring because of two problems. First, the alarm instrumentation

sensed signals from malfunction sensors which were energized by engine

control circuitry only when the engine was operating at greater than 90%

of rated speed. The engine alarm circuitry had no memory capabilities,

so that, when an engine's speed dropped below 90% of operating speed all

alarm sensors were de-energized and could not be sensed by the DAS.

Unless the DAS was recording the alarm data at the exact instant the malfunction signal was occurring (before an engine dropped below 90% speed),

the alarm data was not recorded. (An engine control system also displayed

all alarms only while an engine was running above 90% speed). Ideally,

engine malfunction signals should be available for DAS recording and for

the plant indication whether or not an engine is above 90% speed.

Modifications to the engine alarm system to correct those shortcomings

had been under consideration by the plant operator but were not implemented .

10.6 GENERAL REMARKS

Site measurement problems experienced can be divided into three categories: (1) Problems caused by difficulties in relaying instrumentation

installation instructions with proper authority to the site contractors

and inadequate control of the quality of workmanship associated with the

installation of the instruments, (2) Problems resulting from field environment and (3) System alterations made by maintenance personnel.

Construction management of the site was initially awarded to Volt, Inc.

who supervised the electrical and plumbing contractors. Instrument

installation instructions and changes were coordinated through the con- struction manager and, on several occasions, through the local unions.

Many of the building contractors had no previous experience in the

installation of precision instruments. Site construction was approximately one third complete when management of site construction was awarded to the Boeing Corp. Much of the non-uniformity in electrical

load distribution within the buildings, with a consequent impact on measurement accuracy resulted because of the difficulty in monitoring and

directing installation at the workman level.

Site environment had an impact on thermal and water flow measurements.

Ventilating air affected two temperature measurements and foreign matter

in the hot water loops fouled several pressure cells. As these problems

were discovered, corrective action was instituted.

44
Large changes in system operation characteristics (large increase in

water flow rates) caused by maintenance personnel substituting over-rated

or under-rated components for defective units caused transducers to malfunction by exceeding their operational range. This problem could have

been avoided if such equipment repair and adjustment had been coordinated

with the measurement personnel.

45
Acknowledgements

This project, from its conception to the time of this report, has covered

more than a five year period. During this time many NBS engineers and

managers have contributed towards its progress. Those whose contributions

have been particularly significant during one or more phases are mentioned

below as an expression of the author's gratitude.

For technical management and direction:

P. R. Achenbach, Division Chief

D. A. Didion, Section Chief, Mechanical Systems Section

L. Galowin, Section Chief, Building Services Section

J. Snell, Manager, Energy Conservation Programs

C. W. Phillips, Manager, NBS/HUD-MIUS Program

For project leadership during the construction phase of the project:

J. B. Coble

For conceptual design of instrumentation system:

L. D. Ballard P. J. Reynolds

R. J. Carpenter L. J. Filippelli

M. E. Kuklewicz

For installation and checkout support:

J. R. Graves

L . Br amme r J. Cohen

B. Shomaker

46
Figure 1 An aerial view of the Jersey City Total Energy Site.

The four apartment buildings are Camci (1) , Descon

(2), Shelley A (3), Shelley B (4). The school (5),

commercial building (6), and plant (7) are also

indicated

.

47
site

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48
Figure 3 The central equipment building which houses the total

energy plant. Five engine-generators are located

behind the six pairs of doors. The central section has

a large door for access to the trash collection system.

Above the doors are air intakes for plant ventilation.

In the top central section behind an accoustic screen

are the chiller cooling towers. The boilers and

chillers are located in the left-most section.

49
Figure 4 The bank of five diesel engine-generators. The

sets of three large cables connect each generator

to the main power bus. Heat recovery exhaust

exchangers are located above the engines.

50
ELECTRIC

POWER

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ELECTRIC

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53

Figure

7

Schematic

of

the

Instrumentation

Monitoring

the

Group"

performance

of

all

five

engine-generators.
CL

54

Figure

8

Schematic

of

the

instrumentation

monitoring

the

individual

performance

of

engine—

generator

1.

Instrumentation

on

engine-generator

2

is

the

same.
BOILERS

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55

Figure

9

Schematic

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monitoring

the

energy

flow

into

and

out

of

the

primary

hot-water

loop

.
EXHAUST

<£U

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56

Figure

10

Schematic

of

primary

water

flow

through

boilers.

Valves

are

provided

to

select

primary

water

flow

through

both

boilers

in

series

or

through
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Figure

12

Schematic

of

instrumentation

monitoring

primary

and

secondary

heat

flow

in

and

out

of

the

site

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water

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Figure

13

Schematic

of

Instrumentation

Used

to

Monitor

Electrical

Energy

Flows

in

the

Plant.

Diagrams

of

Normal

and

Essential

Feeders

to

Individual

Buildings

Shown

in

Appendix.
Figure 14 MCC-1, one of three plant motor control centers. MCC-1

is located in the engine room and distributes power

from the plant essential bus to equipment necessary to

support engine operation. The primary hot water pumps are

are visible in the background.

60
SPACE

HEATING

EXCHANGER

P CCj o a <u p co

61

Figure

15

Typical

Schematic

of

Instrumentation

Used

to

Moni

an

Individual

Building’s

Demands.

Some

Buildings

have

Different

Instrumentation

Arrangements

becau

their

Mechanical

and

Electrical

Contractors

Chose

Different

Designs.
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63

Figure

17

Diagram

of

power

and

voltage

measurements

on

the

CEB

main

power

bus.
Figure 18 Piping diagram of venturi, differential

pressure cell, bleed ports, and calibration

diaphrams. Figure 19 shows a photo of a typical unit.

64
Figure 19 Typical hookup of differential pressure cell

used with venturi to measure flow rates. The

venturi is located above this apparatus as shown

in the Figure 18 diagram. Note the two bleed

valves (A) at the bottom of the photograph and

the two calibration interfaces (B) just above the

pressure cell box.

65
Figure 20 Venturi installed in 10 inch pipe. Downstream

portion of the venturi is covered with pipe

insulation.

66
Figure 21 Venturi cleanout operation. Rod is pushed in and

then returned to clear sediment from the venturi’s

two annular pressure pick-off rings.

67
FREQUENCY PROPORTIONAL TO FLOW RATE

Figure 22 Diagram of the Omniflo turbine flowmeter with a typical output signal.

68
Nutating

Disk

Meters

with

Dial

Indicators

69

Figure

23

Diagram

showing

major

elements

of

fuel

measurement

system.

Nutating

disk

flowmeters

(M)

,
Figure 24 Fuel flowmeter installed on an engine. Flowmeter is

installed between fina] filter and injector rack.

Three gate valves shown allow flowmeter to be bypassed

and isolated from line for servicing, without

disrupted engine operation.

70
Figure 25 Fuel flowmeter installed on a boiler.

71
Counter

resets

on

the

1,024th

pulse

=t GO

h- CD 1 —< o GO

'<r

cvi oT

cq <

VO

CN

d)D

bO

•H

72

ock

diagram

of

scheme

used

to

integrate

turbine

signa

thumbwheel

switch

is

used

to

set N

in

the

divider.
73
Figure 28 Example of thermopile

74
ON/OFF

ALARM

SIGNALS

FROM

ONE

ENGINE

Figure 29 Block diagram of multiple engine alarms

converted to a single signal line.

75
0

Figure 30 The shelter on the Descon-Concordia roof

contains weather station transducers which

measure temperature and relative humidity.

Background is the New York City skyline.

76
vf

'

Figure 31 This pyranometer mounted on the Descon roof

measures direct solar radiation.

77
Figure 32 Indirect solar insolation measurement. This

measurement requires shielding of direct solar

radiation using a "shadow band". The shadow

band must be repositioned every week to correct

for seasonal changes in sun angle.

» tills H

* «| f ! • •

78
Figure 33 The aerovane and tower located on top of

the 17 story Camci building. The aerovane

measures wind speed and direction.

79
Figure 34 Aerovane wind direction and speed indicator.

The propeller is removed to calibrate the

speed indicator using a synchronous motor.

80
Figure 35 The central station of the Data Acquisition

System (DAS) is located in the CEB.

81
Figure 36 The central station of the DAS.

82
Figure 37 Close up view of DAS components. From top to

bottom; digital system clock, digital volt meter,

scanner, scanner control, coupler.

83
Figure 38 Front view of a remote DAS station rack. Each

remote building has a similar cabinet that

contains multiplexing circuitry, thermocouple

reference, and watt transducers.

84
Figure 39 Rear view of a DAS remote station

85
CENTRAL

STATION

Figure

4-0

Block

diagram

of

data

acquisition

system

including

printer

and

modem

output

capabilities.
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lw

>4-1

CO

4-1 CO XIXId

cO

Cfl

i—

l

cOd

00

•H

cn

o

d

4-1 d

o

a

cn<

a

m

o

CJ •H

4-1 cOe

0) 43O

CO

1)d

d

oo

•H

P-»

87

to

the

output

devices.

Two

of

the

eight

remote

slave
Figure 42 The printer provides a hard copy record of

DAS scan data.

88
@49075078NBS@4-90758

80208V+022935 00308V+034945 00140101 V+©25815 00506V+027683 0060©V+036?35

00700V+830205 00800V+0 i 8 (' 35 0109010V+048715 0*0*201V+045395 00381.V—060175

00401V+02293

5

00501V+0i 2695

5

00601, V+0£6855 00701V+034375 00801 V+ 632855

00901V+023625 00282IV+025865 00382IV+014115 0*040*2:V+021995 @0502:V+ 026265

006O2V-01387

5

00702V-018505 00802! V+0*4362

5

0*090*2;V+ 0*33295 00*283:V+632535

00303V—000165 00403 V+bi 19545 00503 V+825335 80*6013 V+02657

5

00703:V+828515

00803:V+023455 00903:V+0i43475 0i 0i 20i 4V+04209

5

0@304V+801855 80404V+017635

00504V+024295 00604V+013385 00704V+034595 00004V+061705 0*090*4 '.,.'+ 880875

00205V+00550

5

0

0

s05V+09250

5

01014015 V+827985 00*505V+02477

5

0*0605V+652995

00785V+05751

5

00805V+02181

5

01 0905V+0i 0954

5

00*206V+889295 00306V+ 04 2*615

00406V+029875 0©5@6V+025445 010160*6 V+029185 08706V+811375 00886V+004395

08906V+037875 0@207V+034545 @0307V+016035 00467V+028315 0050?V+025835

00607V+040115 00707V+037385 @0807'V+00865

5

010190*7 V+061155 00208sV+058105

003@8V+03839

5

004€i8V+028515 0*015018 V+026155 00*6*38 V+0*58995 00708: V+66578

5

00808V+033165 00988V+066225 0020*9V+06564

5

00309V+027595 08489V+028385

@0509V+026455 006019V+012405 @0709V+610* 0*10*5 0*0*809 V+0*0*68 35 88909V+015175

00210V+019735 00310V+031255 00410V+028695 010*510*V+0* 4' 6 7 3

5

00610V+834285

00710V+01853

5

00810V+017085 009101V+034155 00211V+03274

5

08311V+031495

00411V+028955 00511V+0126985 00611V+034415 08711V+03346

5

00811V+033415

00911V+008145 £i£i212V+0101373

5

00312V—000165 06412V+0i25701

5

00512V+026815

00612V+000295 00712V+033405 00812V+013365

5

00*912V+000155 08213V+600675

00313V—000165 00413V+022855 00513V+026255 00613V+000295 06713V+800085

00813V+00012

5

00913V+000155 010 V+066185 011 V+0126765 612 V+067 29

5

013 V+018335 @14 V+038295 015 V+061165 0*16 V+056365 017 V+052225

01.8 V+020345 0H9 V+041125 0201 V+054615 821 V+026505 022 V+82651

5

023 V+019755 024 V+028405.. . - V+020725 0*26 V+864115 027 V+019815

028 V+019855 829 V+0i20i 355 @30 V+051135 031 V+0101 001 01

5

632 V+00*30 35

033 V+02443

5

@34 V+050475. @35 V+0*010 295 0*36 V+05070* 5 ©37 V+032675

038 V+01254

5

039 V+000165 01401 V+002415 041 V+0101 963

5

©42 V—00*3165

043 V+016725 044 V+010101025 0145 V+0132985 646 V+811705 ©47 V+805685

048 V-001685 0149 V—000285 @50 14+035102 051 M+035292 052 M+03'6502

853 M+835092 @54_ 11+837122-.J0S5,

.

14+038102 0*56 14 +0* 3834' 31 057 14+ 83536

2

058 14+036482 @59 M+035222 0601 M+034772 061 14+011012 062 M+610932

063 M+018482 0164 M+011552 065 M+01018092 0*66 M+011052 06 7 14+01 873

2

068 M+009702 0i69 M+009692 070 M+010922 671 M+0G9762 072 14+0184 12

073 14+035242 074 M+0H01702 075 M+0H0542 0*76 M+011732 077 M+012162

@78 1*1+009892 0179 M+010032 @80 Ivt+10i0i60*2 081 M+0*3 970*2 Mo 14+ 8222

7 '2 083 M+154432 ©84. ... 14+ @283±2. .085 11+112772 0i86 M-000442 087 14+018562

@88 M+008752 089 M+017822 0190 M-Q01152 0*91 M+016442 092 14-60 4-692

093 1*1+081042 @94 M+0129662 895 1 *1+20100*02 0196 14— 010*40*0* 2 097 M+026122

098 14+021932 0199 M+031592 100 1*1+015612 101 M+0044 92 102 M-00106

2

103 1 *1-121002 104 14-012732 105 1*1-0*19362 10i6 M-0010*12 107 14+ 01 9032

108 M-800232 1019 1 *1-010101022 110 V+0H453

5

111 V+046785 112 V+04308

5

113 V+000025 114 V+001885 115 V+029195 116 V+033105 117 V+000G85

118 V+044195 119 V+041365 120 V+041305 121 V+041265 122 V+041235

123 V+041195 124 . V+04106

5

125 V+041045 126 V+0*4 101

5

127 V+040985

128 V+040955 129 V+04@845 130* V+040815 131 V+040795 132 V+04 87'65

133 V+040745 134

V+040645- 135 V+0i 40*62

5

136 V+040595 137 V+ G40575

138 V+040545 139 V+040445 1401 V+043305 141 V+048575 142 V+0211 2

5

143 V+089155 144 -V+034@1

5

145- V+045595 146 V+064545 147 V+* yfcj ui 1.

j

148 V+062285 149 V+062195 1501 V+062195 151 V+062175 152 V 0 ,•••* I ...» '.j 153 <*+062135 154 V+062055- 455

V+0*620* 3

5

156 V+0620*25 157 V+061995

158 V+061975 159 V+061885 160 V+004966 161 V+@@0@76 162 V+000026

163 V+004646 164- V+000926 -±65TM V+06010116 166 V+010100* 26 167 V+000026

168 V+800026 169 V+000026 170 V-000043 1 (' 1 V-0@0i 0* 43: 172 V+046255

173 V+045855 174 V+012815’-“±-75—

-

V+01316

5

176 V+013325 1 7 7 V+020005

178 V+825405

Figure 43 Example of printer output.

89
90

Figure

44

Scanner

controller

front

panel

controls.
ooI—l o

CO

4-1 •H60

<0

M-lo

cn I—I On

4-J cOo

0)c

COCl

4JcOu

fJL

in

<)•

a)

J-i 3

60

•H

pH

91
H,

17

18

212170

Figure

46

Schematic

of

relay

multiplexing

cards

in

the

CEB

and

remote

slave

scanners.

10

analog

signal

inputs

are

connected

at

the

top

pins,

relay

select

lines

are

at

the

bottom.
LABEL

-LRN

LABEL

93

Figure

47

Front

panel

controls

of

the

data

coupler.
Figure 48 The DAS digital incremental tape recorder

.

94
Recording

Tracks

1 9

Recorded once at

the beginning of

each scan

Data, 13 characters per channel

Label - 12 characters recorded once

at the beginning of each scan

Time in days, hours, minutes

Channel ID

Subchannel ID

DVM Function - V for DC volts, M for

DC millivolts r —

Pol ari ty — — -

—

DVM Data Magnitude

DVM Range

L

L

L

LL

L

L

L

LL

L

L

LD

D

D

H

HM

M

C

C

C

'c

-IF

-iPXX

X

X

X

t

Magnetic Tape

Motion

Interrecord Gap - recorded only at

the end of a scan IIRG

Figure 49 DAS output format for magnetic tape.

95
Figure 50 Example of fouled bellows in a differential

pressure cell. The accumulation of fouling was reduced by frequent bleeding of the

cell chambers and venturi lines.

96
Figure 51 Nutating disk meters installed in day tank

fuel lines.

97
Figure 52 Portable calibration unit for differential

pressure cells.

98
REFERENCES

1. Monitor Labs Model 10185 Multichannel Data Acquisition System

Technical Manual

2. Monitor Labs Model 1200 Scanner Technical Manual

3. Monitor Labs Model 3100 Digital Clock Technical Manual

4. Monitor Labs Model 4200 Data Coupler Technical Manual

5. Dana Model 4800 Digital Voltmeter Instruction Manual

6. Kennedy Co. Model 1600 Incremental Magnetic Tape Recorder

Technical Manual

7. Thermocouple Guide Book, Pall Trinity Micro Corp., Cortland, N.Y.

99
y
APPENDIX 1 : As-Built Drawings of Site

Facilities and Instrument Locations

A1

3

Schematic

of

CEB

electrical

power

generation

and

distribution.

Locations

of

NBS

instrumentation

are

shown.

CE-5

and

CE-8

are

underground

distribution

vaults

located

outside

of

the

CEB.
LlNfc.

VOUA&&

Al-2

Site

electrical

feeder

distribution

CE-1

thru 7

are

underground

distribution

vaults.
Al-3

Electrical

distribution

and

NBS

instrumentation

locations

in

Shelley

A

and

Shelley

B.

Normal

loads

are

apartment

lighting,

outlets

and

cooking.

Emergency

loads

are

Comdor

lighting,

exit

signs,

fire

alarm

and

pump

sysLem

ana

ac

lease

one

elevator.
oo

Xo

m

2o

u

Al-4

Electrical

distribution

and

NBS

instrumentation

loca

Business

Building,

the

School

and

Pool.
COEUoddoo

co

a) o

<D V- -C r

E-h Pr

CD

co

cO 60

•H

d

X) *H C X O I O »rl c 0 0 JC

CJ1 O' C JC O 4-' CJ

C/3 M0) C Q

0)

X 4-J d c

co a>e

•rH 60

CJ 0) g co co o o d £

•rH CO d X’ O CJ

•rH 03

4-1 0-

cO u

x

d

r

0) c

Ci c

4-> -r CO X d r-

__l 00 ,r PQ

is a; X n-i d

CO <4-C. do a- •h x

•u

x

d co

rCl 4 •H U c o

4-1 CO CO

•rH P X X

•rH

r~H >

cO *H

CJ

X

CC

4-J CD O X

cua1 i—I QJ

_

W U-J

u2< LOC

L


CEB

chilled

water

flow.

"CC-1"

is

the

main

CEB

cooling

coil.

FCs

are

CEB

office

fan

coil

units.
*o

I

I

IL

10i

Al-9.

CEB

absorption

chiller

condenser

water

flow.

CT-1

and

2

are

roof

mounted

cooling

towers.
COOLING COIL

o

~-

A1

10.

Shelley

B

hot

water

and

chilled

water

schematic.
COOLING COIL Z 2 3 O O £ O

Al-11.

Shelley A

hot

water

and

chilled

water

schematic.
COOLING COILS

O

° _ Q- cz >- 5 o

o uj o

cr cd i- _J

SMH

HMH—Kib— ! §

- O H

1- ^ z < I1I!r

< O < Q 111 u

X CE

<n in£

a: CJ X a: a: $

<_> $

X

5

X

4-J

tfl e

a) ,C

CJ

Cfi M

<D

o

40

•H

CJe

c0 O

<

DOMESTIC

HOT

WATER

STORAGE

TANKS
COOLING SYSTEM

J0a

!.(/)(/)< O UJ

J

J00Iu0)

Al-13.

School

and

pool

hot

and

chilled

water

schematics.

The

pool

does

not

use

chilled

water.
o Q *

03o

•HUa

a)

T3

0)

'HV

03C

03O

43Coo

03

0) «

03

(3

03 OOi—i I i—I <
APPENDIX 2 : Data Acquisition List:

A listing of all data channels by

channel number and NBS code number

A2

9/19/77

National Bureau of Standards

Jersey City Total Energy System

Data Acquisition List

DAS NBS Normal Physical Range

CHANNEL CODE Identification DAS mV in parentheses

SPECIAL CATEGORY

HEADING 100 7 characters in the heading of each

scan contain clock data: date (1-365)

and time (0-24 hours plus minutes)

172 102 Time generated by plant 5 minutes (2.82V/5 min)

173 110 Eng. run time EG 1 5 minutes (2.80V/5 min)

when engine is on 174 111 Eng. run time EG 2

177 130 Power factor on CEB bus .5 lag - 1.0 (+5.0V - 0.0V)

178 141 Frequency of total plant output 59-61 Hz (0-5. 0V)

WEATHER STATION - Remote 005

005-00 148 Direct solar radiation Clear Sky (7.5V)

005-01 149 Indirect solar radiation Bright Sky (1.6V)

008-08 150 Wind Direction 0-360 deg (0-3. 6V)

008-09 151 Wind velocity 0-120 MPH (0-12V)

005-04 200 Outdoor baro. pressure 27-31 inches Hg (2.7 - 3.1V)

005-05 710 Outdoor temperature

»

-20° to 120°F (-2.0 to

12.0V DC)

005-06 712 Outdoor humidity 0 to 100% (0 to 10V DC)

005-07 714 Data cabinet ambient temperature

A2-

1
DAS NBS Normal Physical Range

CHANNEL CODE Identification DAS mV in parentheses

PRESSURE CATEGORY (//' s 200 to 299)

010 202 CEB primary hot water system 0 to 100 psi transpressure, at pump outlet ducer range (2-10V DC)

Oil 220 Lub. oil pressure EG-1 Normal Values: 202-55

012 221 Lub. oil pressure EG-2 psi (6.4V) 220,

221-50 psi (6.0V) when

engine is on.

013 230 Exhaust gas back pressure EG-1 Transducer range 0-30

014 231 Exhaust gas back pressure EG-2 inches water (2-10V DC

Normal 20 in. (7.0V)

when engine is on.

FLOW CATEGORY (//'s 300 to 399

All flows determined by Venturi and delta pressure

transducer unless a turbine meter is specified. Delta

pressure cells have 0 to 150" H2 O range (2-10V DC)

.

015 301 Primary water flow to all engines 11,300 lb/min (6.1V)

016 302 Primary water flow from engine 1

jacket

2,200 lb/min (5.0V)

017 303 Primary water flow from eng. 2 jacket 2,300 lb/min (5.2V)

018 304 Primary water flow from Chiller #1 7,500 lb/min (5.1V)

019 305 SHW return from HSP East (Shelley A,.

Shelley B, School, Pool)

8,700 lb/min (6.3V)

020 306 SHW supply to HSP West (Business,

Camci, Descon)

7,000 lb/min (8.2V)

021 307 Condenser water flow inlet to

Chiller CH 1

14,000 lb/min (4.5V)

022 308 Condenser water inlet to Chiller #2 17,000 lb/min (5.9V)

023 309 Total condenser water makeup

024 310 Total chilled water flow to both

chillers

20,000 lb/min (5.5V)

025 •311 Chilled water from chiller #1 10,000 lb/min (6.4V)

030 312 Chilled water or HWR ret. from

plant fan coil units FC-1 thru 5

(Turbine)

A2-2
DAS NBS Normal Physical Pang*

CHANNEL CODE Identification DAS mV in paren these027 313 Chilled water return from main 900 lb/min (4.1V)

CEB air inlet coil CC-1

028 314 Chilled water from HSP East zone 9,000 lb/min (5.5V)

029 315 Chilled water from HSP West zone 9,000 lb/min (3.2V)

026 316 Total raw water from all engines 3,200 lb/min (8.8V)

FUEL CONSUMPTION - DIRECT TURBINE MEASUREMENT

140 360 Engine 1 0-.6 GPM

141 361 Engine 2 0-.6 GPM

142 362 Engine 3 0-.6 GPM

143 363 Engine 4 0-.6 GPM

144 364 Engine 5 0-.6 GPM

145 365 Boiler 1 0-1.5 GPM

146 366 Boiler 2 0-1.5 GPM

147 367 Spare 0-10.24 VDC

A2-3
DAS NBS

CHANNEL CODE Identification

Normal Physical Range

DAS mV in parenthese s

SITE BUILDING FLOW

Flow by venturi and delta pressure

transducer unless a turbine is specified.

All delta pressure cells range 0 to 150 inches

water (2-10V DC).

CEB Secondary Hot Water to Buildings

007-01 327 Shelley A Total Building Return

006-01 328 Shelley B Heating Return

003-01 330 School Heating Hot Water Return

004-01 331 Business Building Total Building Return

002-01 332 Pool Domestic Hot Water Exchanger Supply

009-01 333 Descon Concordia Heating Hot Water in

Winter, Chilled Water in Summer

008-01 334 Camci Total Building Supply

CEB Chilled Water To Each Building

007-03 336 Shelley A Return

006-03 337 Shelley B Return

003-03 339 School Return

004-03 340 Business Building Return

008-03 343 Camci Supply

CEB SHW To Building Domestic Heat Exchanger

007-05 345 Shelley A Supply

006-05 346 Shelley B Return

003-05 348 School Return (turbine)

004-05 349 Business Building Return (turbine meter)

009-03 351 Descon Return

008-05 353 Camci Supply

A2-4
DAS NBS Normal Physical Ra: CHANNEL CODE Identification DAS mV in parenthe:

ELECTRICAL SIGNALS

Voltage (//’ s 400 to 499)

160 400 CBB main bus line voltage, 0A-B 480V AC (12.0V DC)

163 410 PSE&G feeder in CEB, utility side 480V AC (12.0V DC)

007-08 416 Shelley A PN5 voltage 480V AC (6.0V DC)

006-08 420 Shelley B PN4 voltage 120V AC (6.0V DC)

003-08 424 School PN3 voltage 277V AC (2.77V DC)

009-07 426 Descon-Concordia PN2 A3 480V AC (6.0V DC)

009-08 428 Descon-Concordia PN2 Al,2 120V AC (6.0V DC)

008-08 430 Camci PN1 voltage 480V AC (6.0V DC)

004-08 432 Business Bldg. PN1 voltage 277V AC (6.0V DC)

Integrated Power (#’s 500 to 549)

110 501 Total plant production 500-1300 kW

111 502 GEN //I Production 200-450 kW

112 503 GEN if 2 Production 200-450 kW

113 509 PTC Compactor Load

114 510 LP-1 12-16 kW

115 511 MCC-1 100-150 kW

116 512 MCC-2 30-50 kW

117 513 MCC-3 150 kW in summer

118 514 PTC

007-07 515 Shelley A PE2 30-40 kW

007-06 516 Shelley A PN5 180-350 kW

006-07 519 Shelley B PE2 10-20 kW

006-06 520 Shelley B PN4 40-110 kW

002-04 522 Pool PN3

003-07 523 School PE3

003-06 524 School PN3

009-04 526 Descon-Concordia PN2, A3 40-100 kW

009-05 527 Descon-Concordia PEI, A3 40-45 kW

009-06 528 Descon-Concordia PN2, Al,2 50-150 kW

008-07 529 Camci PEI 30-40 kW

008-06 530 Camci PN1 100-200 kW

004-07 531 Business Bldg. PEI

004-06 532 Business Bldg. PN1

A2-5
DAS NBS

CHANNEL CODE Identification

Normal Physical Range

DAS mV in parentheses

Instantaneous Power

041

042

043

044

045

046

047

048

049

550

551

552

553

554

555

556

557

558

DC voltage proportional to KW (0-10V DC)

Total Plant Production

Generator #1

Generator //2 PTC Compactor

LP-1

MCC-1

MCC-2

MCC-3

PTC

700-1200 kW

200-350 kW

200-350 kW

18-21 kW

125 kW

38 kW

150 kW summer

TEMPERATURE CATEGORY pTs 600 to 799)

Actual temperature signals originate from a single

thermocouple junction, delta (DT) measurements from

a pair of multi-junction piles. Signal levels are -10 to +10 mV. All are type T copper-constantan

unless otherwise noted.

050 600

A, B , C

(Actual) PHW temp, to all engines 175-195°F

086 601 (DT) PHW between engine 1 jacket

water inlet & outlet (600C & 603)

3-6°F ON

-1 OFF

087 602 (DT) PHW between engine 2 jacket

water inlet & outlet (600B & 604)

3-6°F ON

-1° OFF

051 603 (Actual) PHW outlet from EG-1

jacket

Inlet plus 3-6°F

052 604 (Actual) PHW outlet from EG-2

jacket

Inlet plus 3-6°F

089 605 (DT) PHW supply and return all

engines (600A)

3. 5-6. 0°F

080 612 (Actual) exhaust gas temp, in

boiler 1 stack, iron constantan

300-460°F ON

160°F OFF

081 613 (Actual) exhaust gas temp, in

boiler 2 stack, iron constantan

300-460°F ON

160°F OFF

090 614 (DT)—PHW- across EG-1 jacket plus

M-l (600A)

4. 5-7.0 ON

091 615 (DT) PHW across EG-2 jacket plus

M-2 (600C)

4. 5- 7.0 ON

A2-6
DAS

CHANNEL

NBS

CODE

053 616

054 617

055 627

A,B,C

092 628

056 629

057 630

093 631

094 632

058 633

095 634

096 635

059 636

097 637

060 640

093 641

099 642

100 647

A,B

101 659

102 660

Identification

Normal Physical Range

DAS mV in parentheses

(Actual) PHW outlet from M-l 195-215°F

(Actual) PHW outlet from M-2 195-215°F

(Actual) PHW outlet of both boilers,

inlet to the chillers.

195-225°F

(DT) PHW across B-2 inlet & outlet

(627C)

-1 to 14 °F

(Actual) PHW inlet to HX-1, 1-A,

outlet of chillers

170-195°F

(Actual) PHW inlet to DCJW, outlet

of HX-1, 1A

165-195°F

(DT) in PHW main line caused by

DCJW (630)

. 3-1 . 0°F

(DT) PHW across inlet & outlet of

HX-1, 1A (629&630)

10-18°F winter

(Actual) PHW inlet to boilers 170-195°F

(DT) PHW across inlet & outlet,

CH-1 (627B)

8-20°F

(Actual) PHW outlet of DCJW

(uses well 631)

170-185°F

(DT) PHW across inlet & outlet of

both boilers (633 & 627A)

5-15°F

(Actual) mixed outlet of both SHW

heat exchangers, SHW to site.

175-190°F

(DT) across East site SHW supply &

return (640)

7-15°F winter

(DT) across west site SHW supply &

return (640)

12-21°F winter

(DT) CHW or HW across CEB office fan

coil supply & return

(DT) across East site CHW supply and 1-5 °F

return

(DT) across West site CHW supply and

return

A2-7

1-5°F
061

062

063

103

064

065

066

067

104

105

068

1

069

106

070

088

107

071

072

073

NBS

CODE

661

662

663

A,B

664

A, B

665

671

672

Identification

(Actual) CHW outlet CH-1

(Actual) CHW outlet CH-2

(Actual) temp, chilled water to

site West zone

(DT)across CC-1 supply & return

Normal Physical Range

DAS mV in Parentheses

42-50°F

42-50°F

42-50°F

(Actual) CHW to inlet of both 45-55°F

chillers.

(Actual) condenser water makeup 65-75°F

(Actual) condenser water inlet to 75-85°F

CH-2

673

674

675

690

A, B

691

692

693

A,B,C

694

695

696

700

701

(Actual) condenser water inlet to 75-85°F

CH-1

’(DT) condenser water temp between 2-12°F

inlet & outlet CH-1 (673)

(DT) condenser water temp, between 2-12°F

inlet & outlet CH-2 (672)

(Actual) raw water inlet to all 70-85°F

engines

(Actual) raw water supply manifold 70-85°F

after E-l outlet, before E-2 inlet.

(DT) between inlet and outlet of -.2°F

raw water pumps. (693A)

(Actual) raw water temp, downstream 75-85°F

of all engines —total engine outlet

(DT) RW across HWPS and HC-1 plus .2°F

RHC-1 thru 3 (693B)

(DT) RW between total engine outlet

and DCRW outlet (693C) 6-8°F

(Actual) Raw water supply manifold 70-80°F

after E-2 outlet, before E-3 inlet.

(Actual) lub. oil sump Eng. 1 120°F OFF, 180°F ON

(Actual) lub. oil sump Eng. 2 120°F OFF, 180°F ON

A2-8
DAS NBS Normal Physical Range

CHANNEL CODE Identification DAS mV in Parentheses

108 702 (DT) RW across HX-3 (690A)

109 703 (DT) on RW supply manifold across

E-l (691 & 690B)

1.5°F ON

074 711 (Actual) engine room air temp, db 75-85°F

075 713 (Actual) engine room air temp, wb 60-75°F

076 730 (Actual) fuel oil supply to all

engines

84-93°F

077 731 (Actual) fuel oil return from all

engines

. 85-94°F

078 732 (Actual) fuel oil supply to boilers 70-81°F

079 733 (Actual) fuel oil return from

boilers

71-82°F

082 750 (Actual) temp, of exhaust gas 480-600°F ON

entering M-l, iron constantan 130°F OFF

083 751 (Actual) temp, of exhaust gas 480-600°F ON

entering M-2, iron constantan 130°F OFF

084 752 (Actual) temp, of exhaust gas 400-500 ON

leaving M-l, iron constantan 130°F OFF

085 753 (Actual) temp, of exhaust gas

leaving M-2, iron constantan

400-500°F ON

WATER TEMPERATURES AT SITE BUILDINGS

(Actual) Chilled Water To Individual Buildings

006-09 643 Shelley B (well 650A) 42-50°F for all

007-10 644 Shelley A (well 648A) buildings

008-10 645 Camci (well 654A)

009-09 646 (Actual) Hot or chilled water for

•9 heating or cooling (well 626A)

003-09 624 School

004-10 625 Business Building

A2-9
DAS NBS Normal Physical F CHANNEL CODE Identification DAS mV in Parent!

(DT) Chilled Water Between Building Supply And Return

Well A is Supply, B Return

007-02 648 Shelley A

006-02 630 Shelley B

003-02 651 School

009-00 626 Descon Heating and Cooling

008-02 654 Camci

004-02 655 Business Building

(Actual) CEB SHW To Buildings

002-08 760 Pool domestic 170-190°F for all

003-10 761 School heating supply build ings

004-11 762 Business Bldg. Total Bldg, supply

006-10 763 Shelley B Total Supply

007-11 764 Shelley A Total bldg, supply

(uses well 768)

008-11 765 Camci Total bldg supply (uses well 774)

(DT) Between HWS and HWR

007-00 768 Shelley A total building

006-00 770 Shelley B total building

003-00 771 School heating

002-00 772 Pool domestic

008-00 774 Camci total bldg.

004-00 775 Business bldg, total bldg.

(Actual) HW Temperature Inlet To Domestic Heat Exchanger

003-11 781 School 170-190°F for ail

004-12 782 Business bldg. buildings

006-11 783 Shelley B

007-12 784 Shelley A

008-12 785 Camci

009-10 786 De scon-Concord ia

(DT) Hot Water Inlet and Outlet of Domestic Heat Exchanger

007-04 788 Shelley A

006-04 790 Shelley B

003-04 791 School

009-02 793 De scon-Concord ia

008-04 794 Camci

004-04 795 Business bldg.

A2-10
DAS

CHANNEL

NBS

CODE Identification

Normal Physical Ran;

DAS mV in Parenthesf

ALARMS AND INDICATORS (//' s 800 to 899)

Engines

127 800 Engine low oil pressure, malfunction Engine 1 --(2.58V)

801 Engine high water temperature,

malfunction

(1.29V)

802 Engine high oil temperature, malfunction (.65V)

803 Engine overspeed (110%) (.32V)

804 Engine underspeed (90%) (.16V)

805 Engine excessive vibration malfunction ( .08V)

120 806 Engine high oil coolant temperature Engine 1

--(2.58V)

807 Circuit breaker trip (1.29V)

808 Engine excessive start time (.65V)

809 Generator overload ( .32V)

810 Failure to parallel (.16V)

811 Reverse power protection ( .08V)

121 815 to

820 (Same as 800 to 805) Engine 2

122 821 to

826 (Same as 806 to 811) Engine 2

123 830 to

835

(Same as 800 to 805) Engine 3

124 836 to

841

(Same as 806 to 811) Engine 3

125 845 to

850

(Same as 800 to 805) Engine 4

126 851 to

856

(Same as 806 to 811) Engine 4

128 860 to

865

(Same as 800 to 805) Engine 5

129 866 to (Same as 806 to 811) Engine 5

871

A2-11

APPENDIX 3 : Specifications for the NBS

Data Acquisition System

A3

SPECIFICATION FOR THE NBS DATA ACQUISITION* SYSTEM NO. 2672

I. GENERAL

A. Site Description

The x data acquisition system described herein will be used to collect

data on energy use and total energy plant operations on the Jersey City

Operation BREAKTHROUGH site. This site includes a total energy plant

which serves a residential complex of four medium to high-rise apartment

buildings, two schools, about 5000 sq. ft. of light commercial space,

and a swimming pool. Overall site dimensions are approximately 1400 ft.

b6 700 ft. (See Appendix A for site layout.)

The total energy plant is built around five 600 kilowatt diesel

generators which produce all the electricity for the site. The heat

from the cooling water and exhaust gases ‘of the diesel generators is

used to heat, air condition (utilizing absorption chillers), and provide domestic hot water for the site buildings. Supplemental heat

-for these uses is produced by two 400 horsepower hot water boilers.

Chilled water is produced by two 526-ton absorption chillers.

The electricity, chilled water, and hot water are generated in the

Central Equipment Building (CEB) which is located in the center of the

site. All services are distributed from the CEB to other site buildings

in underground conduits. Electricity is generated and distributed at

480 volts, three phase, sixty hertz, three wire delta. In each building

the 480 volts are transformed down to 208/120 four wire wye.

Chilled water is pumped from the CEB to each building except the

poo]^. The chilled water leaves the CEB at 44° F and returns at 58° F.

In each building, booster pumps distribute the chilled water throughout

the building.

Hot water is generated through a closed heat exchanger with the

jacket water from the diesels. The hot water is pumped to each

building on the site. The hot water leaves the CEB at 200°F and

returns at 180°F. In each building, booster pumps distribute the hot

water for space heating and for domestic hot water generation.

B. Data Acquisition System

The Data Acquisition System (DAS) which is further defined herein

is to be used to collect and record, on computer-compatible magnetic

tape, energy use and related data from government-supplied measurement

devices located in the CEB and all other site buildings. Appendix B

is a complete list of the inputs to the DAS. Typical measurements in

A3-
-2-

the CEE are the following: on two of the diesel engine generators - watt-hours, frequency, power factor, fuel, flow, engine cooling water

flow and temperature, heat recovery muffler water temperature and

exhaust gas temperature; on all engine-generators - all alarm signals;

alarm signals from the site’s pneumatic trash handling system; weather

data; and time and date.

Appendix C shows schematically the data that will be collected

from each remote building. Typical data in a building are as follows:

watt-hours on the normal and essential load feeders, secondary

voltage (208) on each feeder, chilled water flow from the building,

chilled water return and differential temperatures, hot water flow

from the building, return and differential hot water temperatures,

hot water from the domestic hot water heaters, return and differential

domestic heating hot water temperatures.

C. Site Conditions *

All wire or cable runs between remote buildings or to the CEB

must be made in a government provided instrumentation raceway and in

a> government provided non-ferrous conduit which is located approximately 2 feet from and in parallel with the site electrical distribution system; said system being 480 volts, 60 cycles, 3 phase, with

ampere loadings as referenced in Appendix A.

II. DATA ACQUISITION SYSTEM REQUIREMENTS

This specification describes the minimum requirements necessary

for the DAS to accomplish the end result of providing data from all

measurements on magnetic tape in a computer-compatible format convenient for subsequent analysis and evaluation.

All systems or system manufacturers must meet or exceed the

following or equivalent requirements.

A. Number of Channels

1. Equipment located in the CEB shall monitor and record data

from all 300 individual channels-approximately 170 of which are

located in the CEB, the balance in the other site buildings. The

system must be expandable to monitor -a total of 1000 channels.

(See Appendix b.)

• 2. Equipment in each of the remotely located buildings must

convert data on 13 channels from low level signals (see II. D. 2) to

0 to 5 volts or to digital signals for interference-free transmission

over distances of up to 1000 ft. to the central monitoring and recording

equipment in the CEB. This equipment must be expandable to 30 channels

per building without adding to the inter-building wiring.

A J-2
-3-

B. System Scan & Interrogation

1. .Equipment located in CEB shall scan all measurement

channels continuously, including those which are input from the

remote buildings. System scan rate shall be a minimum of 20

readings per second.

2. The system shall have the capability of operator (front

panel) or automatic selection (relay) of single, repetitive, or continuous scan (interrogation) modes. The single scan mode will cause a. single

interrogation of all system channels and will record the beginning

time of scan and the data from each channel. The repetitive interrogation mode .will cause the single interrogation mode to be executed

at the end of each time period as described in Section C. The continuous interrogation mode, will cause a series of single interrogation

modes to be executed at the fastest possible rate and will continue to

be repeated until the cause of the automatic continuous mode selection

is removed or until operator intervention. If the continuous/single

mode selection is made through automatic external means when such is

removed, the system shall return automatically to the mode of operation

in which it was in at the time just prior to the automatic continuous/

single mode selection.

%

• 3. Channel selection will be 000-999 for the first channel and

000-999 for the last channel, front panel controlled.

C. Clocking

1. Provision shall be made to allow operator to select the channel

interrogation rate. This rate control shall make it possible to select

any time interval from five minutes to two hours. This time selection

shall cause all channels to be interrogated repetitively at the end of

each such time interval, and the data from each to be recorded.

2.. System shall include an internal clock so that the day, hour,

and minute is recorded along with the data from every channel on each

scan. The clock shall visually display days, hours, minutes and

seconds with an accuracy of + 2 x 10“6 seconds and with a drift of

1 ppm/week. The clock shall be battery-backed to provide 4 hours

operation in the event of power failure.

D. System Input

1. System shall have the following electrical accuracy and electrical

noise rejection capabilities when operating as an installed or completed

system subject to external site influences:

a. Transducer to recording device accuracy of .1% of full scale for

any input from 1 millivolt full scale to 1000 volts full scale.

The following are considered necessary to achieve this accuracy:

A3 -3
~4~

(1) Transducer to first active device common mode noise

rejection (CMR) of 120 db; and a common mode voltage

‘rejection of up to 300 volts.

(2) Transducer to first active device normal mode noise

rejection (NMR) of -48 db minimum when the system is

operating at a scan rate of 2p readings per second.

If provision is made for an optional slower scan rate,

normal mode rejection at the slower scan rate shall be

no less than 100 db from the transducer to the first

active device.

(3) Analog to digital converter shall have a minimum of

120 db CMR and 140 db CMR with a filter.

b. Block diagrams of typical government-provided transducers which

provide input signals to the DAS are included as Appendix D.

2. Outputs from the government-provided transducers consist of the

following:

Approximate Number of Channels Output Signal

48

50

43

• 70

33

up to 20

0 to 1 millivolt

0 to 100 millivolt

0 to 1 volt

0 to 5 volt

4 to 20 milliamps

Switch closures

.Switch openings

E. Output

1. The data recording device shall have the following capabilities

when installed and operating in the system:

a. Recording device shall be a reel type, 7 or 9 track, 800 bits

per inch maximum, synchronous or incremental, Univac 1108 computer compatible on magnetic tape; and shall be able to accept

without modification a minimum standard magnetic tape reel size

of 2400 feet.

b. Recording device shall be capable of recording a minimum of 4

days of data on a single tape reel which includes the time (days,

hours, minutes), channel identification number, and channel

data from scans repeated every five minutes with each scan consisting of up to 300 measurement channels.

c. Provision shall be made for entering manual header information

consisting of a minimum of six characters on the magnetic tape.

This information shall be enterable at appropriate times without

interrupting system scan.

A3-4
-5-

d. Tape recorder must be capable of generating inter-record gaps of

a length which may vary from 1 to 999 characters.

e. Information as recorded on the magnetic tape shall include

parity.

2. Equipment located at the CEB shall have the capability of visually

displaying the data from any desired single channel including those being

input from the remote buildings by manual selection of the channel identification from the equipment panel, without interfering with the scan speed.

This displayed data shall be self-updating at a speed no faster than the

ability of the eye to read.

3. Contact closure, upon system shutdown.

F. Computer Control

The data recording system shall have the future expansion capability

for addition of an on-site computer for system control and data analysis.

This is not to say that the system described here shall be a computer,

but rather that the system described shall be computer compatible.

G. Desirable Options (Add-On)

The data recording system shall have the specific peripheral attachment

options as follows:

a. High speed printer

b. C.R.T. display

c. Emergency power supply

d. Teletype and paper punch which does not slow down the system.

The items listed above are not to be included in the basic data acquisition system; however, the system shall be so configured as to permit add-on

of the items listed at the option of the government at any time.

H. Racks

The entire data acquisition system, including the remotely located equipment, shall be furnished completely installed in first quality, tamper

proof racks or cabinets. These cabinets or racks shall be of such a design that access, via hand operated locked latches on hinged doors, to

all equipment contained therein may be made easily by authorized personnel within a time duration not in excess of two seconds. Equipment cabinets or racks shall be burr free, contain no sharp edges, and be painted

consistent with the installation surroundings.

*1. Installation

The manufacturer shall, in addition to delivering the equipment described

above, be responsible for the following:

A3-5
-6-

1. Provide for and supervise the electrical installation of government

supplied transducers and associated transducer power supplies. The government will supply all transducers (approximately 300) and transducer power

supplies; and make certain that proper provisions have been made for the

mechanical installation of the transducers.

2. Provide for and supervise the electrical connection of all transducers to the data acquisition system. Transducers are a 3-wire output

type and, in some cases, will require input power connections. The government will supply all transducer connection wire and transducer end

connectors. The manufacturer will supply all mating connectors for the

data acquisition system. Government provided transducers include the

following: • .

Approx.

Use Type Input Power Number

KWH Hall effect AC 27

Fuel Turbine AC 10 . Heat Transfer Venturi DC 37

Temperature Thermocoup le - 105

Alarm Digital DC 90

(combines to 12

analog outputs)

Pressures D.P Cell DC 8

Weather Data - AC 5

Hisc. — — 50

3. Provide for and supervise the connection of all components of the

data acquisition system as supplied by the manufacturer. The government

is providing twisted pair shielded wire. If a vendor wishes to use other

wire, such bids should include cost of wire. The manufacturer will

furnish all necessary connectors, distribution panels, and miscellaneous

items necessary to perform this function. All connectors will be terminated in a neat and orderly fashion such that spare wires, cables, data

channel wires, and other required wires are readily identified and usable.

4. Assume complete responsibility for the correct identification

hookup, and end-to-end operation of the entire data collection system,

exclusive only of the transducer outputs at the point of egress from the

transducers.

5. Furnish all electrical or electronic equipment necessary to allow

for proper data entry into the data acquisition system, and any recording

of said data.

J. Warranty

1. Performance of the system for acceptance by the government will

be determined by its response in all modes of operation.

2. The warranty period shall begin after government acceptance of

the system as described above and shall continue for a period of not

less than 1 year. The warranty shall cover all service, maintenance.

A3-6
-7-

labor, parts, and miscellaneous items which may from time to time become

defective or cause a system failure or partial failure.

r 3. Service shall be provided* during the warranty period and spare

parts shall be maintained by the equipment manufacturer such that arrival

of service personnel shall not exceed 5 hours and that delivery time of

spare parts shall not exceed 12 hours. In no event can the government

tolerate a single down time of the system of greater than 12 hours or an

accumulated weekly down time in excess of 12 hours. Accumulated yearly

down time shall not exceed 7 days. It is anticipated that the system

will be in operation unattended 24 hours a day continuous in excess of

2 years. Service shall include preventive maintenance checks in accordance

with recommended procedures, and shall be provided within one or two weeks

before Christmas and Thanksgiving.

4. Provision shall be made for an extension of the warranty for

additional two (2) year periods.

K. Training

Furnish training and schooling of operating personnel in the proper

operation, technical principles, trouble shooting for minor repairs, and

maintenance of all manufacturer furnished equipment. It is anticipated

that approximately six personnel will require such training. Proposals

shall include number of hours needed for schooling.

L. Drawings and Specifications

Respondees shall provide complete technical specifications and descriptions

of equipment offered and shall also provide operation and maintenance manuals

and spare parts listings.

M. Capability

Any proposed manufacturer must demonstrate that his particular company

has built and serviced similar systems for two years and that a system

similar to that offered has been in continuous operation for a time period

sufficiently long (one year minimum) to indicate to the satisfaction of

the purchaser that the equipment will in fact perform satisfactorily and

reliably.

Attachments

The attached drawings and tables form a part of this specification and

must be considered with respect to all offers concerning the described

data acquisition and recording system and associated labor and responsibilities.

DER/LDB/JES

421.13

5/3/72

A3-7
Newark

Avenue

aoo

JERSEY

CITY

BREAKTHROUGH

SITE

TOTAL

ENERGY

DATA

ACQUISITION

SYSTEM

LOCATION

OF

COMMUNICATION

DUCTS

AND

ELECTRICAL

LOADING
4/7/72

Appendix B

National Bureau of Standards

TOTAL ENERGY SYSTEM • Data Acquisition List

NBS Code

Number

Identification

Soecial Cateeorv (time. of. Hz. wind. #’s 100 to 199)

100 Time (standard) 00:00:00 to 24:00:00

101 Date 1 to 365

102 Time generated by plant

110 Eng. run time EG 1

111 Eng. run time EG 2

120 Eng. speed EG 1

121 Eng. speed EG 2

130

. pf on individual generator G-l

131 pf on individual generator G-2

141 Frequency of to^tal plant output

147 Descon-Concordia valve setting, winter or summer

148 Direct solar radiation

149 Indirect solar radiation

150 Wind direction

151 Wind velocity

Pressure Category (v*s 200 to 299)

200

202

Baro. press, ambient

Press, of system water near boiler (pump discharge)

220

221

Lub. oil pressure individual eng.

it ii it it • it •

-

230

231

Exhaust gas back pressure individual engine

it ii ii ii u ii

240

241

Chiller vacuum CH-1

" " CH-2

£ 3-9
B-2 A/7/72

• Flow Category (fl*s 300 to 399)

301 Primary water flow return to all engines

302 it ti from engine 1 jacket

303 it IS it it it 2

*• 304 •i *1 i« " chiller No. 1 305 SHW flow return from HSP East

306 *i it ti " " West

307 Condenser water flow inlet to chiller CH 1 (CTS)

308 " " " ” " " CH 2 (CTS)

309 Total condenser water makeup (CTS)

310 Total chilled water flow to both chillers

311 Chilled water from chiller CH 1 312 ii ti or HVR ret. from plant air temp. coils (FC~ 1 to FC-5

313 n n return from fan coil unit CC-1 * 314 ii «• from HSP East zone

315 tt it ii ii West " 316 Total raw water to all engines

317 Fuel flow to boiler 1 (turbine meter)

318 it ii from boiler 1

ii it 319 n ii to boiler 2

•i ii 320 it it from boiler 2

it ii 321 n ii to all engines total (FOS) ii 322 it it from all engines total (FOR) ii it 323 ii it to individual engine 1

it ii 324 •i it from individual engine 1. ii n 325 ii ii to individual engine 2

ti ii 326 ii it from individual engine 2

it it

(Total sec. HW flow, heating hot water at each bldg)

327

328

329

330

331

332

333

334

(Chilled water on each building line)

336 Shelley A

337 Shelley B

338 Pre School

339 School

340 Commercial

343 Camci

Shelley A (east)

Shelley B

.Pre School

School

Commercial

Pool

Descon Concordia - Flow to Bldg A3-A1 CHWS and HWS

Camci

A3- 10
B-3 • 4/7/72

' (Flow, domestic hot water generation in buildings)

345 Shelley A

346 Shelley B

• 347 Pre School (turbine meter)

348 School n it 349 Commercial h tt

0 350 Pool II II 351 Descon

353 Camci

Electrical (voltage) (ff’s 400 to 449)

400 Voltage, plant bus

.410 n PSE&G bus

415 Volt, PE2 Shelley A (essential)

416 it PN5 n it (normal)

417 it PE2 Preschool

418 it PN4 ii 419 it PE2 Shelley B

420 it PN4 it ii 421 n PN2 Pool

422 n PN3 ti 423 it PE2 School

. 424 ii PN3 ii

426 it PN2 East Descon-Concordia

427 tt PEI it n ii 428 it PN2 West " ii 429 •ii PEI Camci

430 ii PN1 ii 431 it PEI Commercial

432 ii PN1 it

Watt (#’s 500 to 549)

500 KW

501 KW

502 KW

503 KW

509 KW

510 KW

511 KW

512 KW

513 KW

514 KW

515 - KW

516 KW

517 KW

518 KW

519 KW

520 KW

total plant production

total plant production

GEN £1

GEN #2

used by PTC compactor

used by LP1

used by MCC-1

used by MCC-2

used by MCC-3

PTC

PE2, Shelley A (east)

PN3, Shelley A (east).

P£2, Preschool

PN4, Preschool

PE2, Shelley B

PN4, Shelley B A3- 1

1
£-4 4/7/72

522 KW PH3

523 KW FE2

524 KW PN3

525 KW PE2

526 KW PN2

527 KW PEI

528 KW PN2

529 KW PEI

530 KW PN1

Pool

School

School

Pool

East Descon- Concordia,

n it ii West Descon-Concordia,

Camci

ii 531 KW PEI Commercial

532 ~KW PN1 "

A3

A3

A1

Temperature Category (#*s 600 to 799)

(Actual) means one T.C. reading, real. temp.

(AT) means differential temp.

600A (Actual) PHW temp, to all engines

600B

600C

601 (AT) Jacket vater inlet A outlet engine (EG-1) (600 A 603)

602 (AT) " " “ " " « (EG-2) (600 A 604)

603 (Actual) PHW outlet from engine EG-1

604 (Actual) " " «* « EG-2

605 (AT) PHW supply and return all engines (600A)

612 (Actual) exhaust gas temp., boiler (B-l)

*- 613 (Actual) « " " « (B-2)

614 (AT) PHWR across EG-1 & M-l (600 B)'

615 (AT) ” " - EG- 2 A M-2 (600C)

. 616 (Actual) temp. PHW outlet from muffler (M-l, EG-1)

617 (Actual) " " " •• " (M-2, EG-2)

626A

626B

627A

627 B

627C

.628A

628B

629

630

631

632 ’ 633

634

635

636

637

640

641

642

(AT) water temp, to and from Descon A3-A1 heating & cooling

(Actual) PHWS total from boilers 6 inlet chillers

^T) PHWS between boilers 6 total from boilers (628B)

(Actual) PHWS temp, prior to-HX-1, HX-2 inlet abs.

(Actual) temp, to dry coolers

(AT) HWR from dry coolers and to dry coolers (630)

(AT) temp, outlet coil & inlet to coil HX-1 (629) 6 (630)

(Actual) temp. PHW inlet to boilers

(AT) HWR & inlet to chillers (627B)

(AT) from outlet DCJ-1 A 2, and to 6Q0B

(Actual) temp, on return line from dry coolers (uses well 631)

(AT) temp, inlet to boilers & from boilers (VtlO's 633 to 627A)

(Actual) temp, supply secondary HW coil (on primary line before

E-W split)

(AT) return secondary HW coil A supply (640), East zone

(AT) i» ii «i ii ti so West zone

A3-12
B-5 4/7/72

(Actual) CWS to individual buildings

644 Shelley A (east bldg)

645 Camel

646 (Actual) temp, supply in Descon pump room near F333 (uses well 626]

647A (AT) from TE plant air tempering coils 6 supply SHW coil FC-1 to F(

647B

(AT) CWS from building supply & CWR building return

648 AAB Shelley A (east bldg)

649 AAB Preschool

650 AAB Shelley B

651 AAB School

654 AAB Camci

655 AAB Commercial

658 Reference number for TW at end of AT's

659 (AT) chilled water return from site and to East zone (663B)

660 (AT) " " " " » " " West zone (663A)

661 (Actual) chilled water chiller CH-1 to site

662 (Actual) ” " " CH-2 to site

663A (Actual) temp, chilled water to site West zone

663B

664A (AT) chilled water from air tempering coil CC-1 A to site

664B

665 (Actual) CHWR to CH-1 A CH-2 after AS-4

\

- 671. (Actual) condenser water temp, makeup

672 (Actual) " " ” inlet absorber CH-2

673 •

* (Actual) " " « « " CH-1

674 (AT) condenser water temp, between inlet A outlet absorb. CH-l(w/{

675 (AT) " *' « " " " « CH-2 (w/

(

69 0A

690B

691

.692

693A

693B

693C

694

695

696

(Actual) temp, raw water coolant inlet to engines

(Actual) temp, raw water coolant on line between 2 eng. EG-1 A 2

(AT)' raw water coolant in heating and after pumps (693A)

(Actual) .temp, raw water* between pumps and engines

(AT) raw water from engines and to DCRW inlet (693B on main line

(AT)v/693C and on line after DCRU-1 A 2

(Actual) temp, raw water coolant on primary line between EG-2 A

700

701

702

703

(Actual) lub. oil, individual eng. 1

(Actual) lub. oil, individual eng. 2

(AT) raw water coolant outlet A outlet of HX4 (690A)

(AT) 11 " ** V M .on line between 2 engs. (691 tx •

A3- 13
710

711

712

*713

730

731

732

733

750

751

752

753

764

765

768

769

770

771

772

. 774

775

784

785

788

789

790

791

792

793

794

795

B-6 4/7/72

(Actual) outside ambient db

(Actual) engine room air temp, db

(Actual) outside ambient vb

(Actual) engine room air temp, wb

(Actual) fuel oil at engines supply FOS

(Actual) ' 8

. " ' “ " return FOR

(Actual) ** " " boilers supply

(Actual) 11 " " *' return

(Actual) temp, of exhaust gas on engine entering H1

(Actual) »' " « « " " »* M-2

(Actual) " M " " leaving muffler heat exchangers M-l

(Actual) •' u M " " •• 9! 91 M»2

(Actual) HWS to individual buildings

Shelley A (east bldg)

Camel

(AT) at individual buildings HWR’s & HWS’s (totals)

A&B Shelley A

A&B Preschool

A&B Shelley B

A&B School

A&B Pool

A&B Caznci

A&B Commercial

(Actual) HW temperature inlet to domestic HW generation

Shelley A (east bldg)

Camel

.(AT) Hot water inlet and outlet of domestic heat exchangers

A&B Shelley A

A&B Preschool

A&B Shelley B

A&B School

A&B Pool

A&B Descon-Concordia

A&B Camel

A&B Commercial

A3- 14
B-7 4/7/72

Alarms and Indicators Category (ff's 800 to 899)

800

801

802

803

804

805

806

807

808

809

810

811

812

813

Engine low oil pressure

Engine high water temperature

Engine high oil temperature

Engine overspeed

Engine underspeed

Engine excessive vibration

Engine high oil coolant temperature

Circuit breaker trip

Engine excessive start time

Generator overload

Failure to parallel

Reverse power protection

Overvoltage

Undervoltage

815 to 828

830 to 843

845 to 858

* 860 'to 873

(Same as 800 to 813)

(Same as 800 to 813)

(Same as 800 to 813)

(Same as 800 to 813)

Solid Waste Collection System (PTC) Category (ff's 900 to 950)

901 Differential pressure

902 Power record

903. Velocity pressure recoi

904 «« it n 905 n it tt 906 \

it it it 907 tt it ~ it 908 • Static pressure record

909 it it n 910 it it tt - 911 it it tt 912 it ••• tt 913 it it •t 914 it •t it 915 it it it. 916 tt it •• it 917 Static pressure

918 it •i 919 it it 920 *» • it 921 ' tt tt • 922 n it • 923 n tt 924

925

ti

it n

It A3- 15
B-8 4/7/72

926 Signal processor

927 Spare

928 n 929 n 930 «i (29 channels 0-1.25 volts DC, and one channel 0-18 volts DC)

I

A3-16
Appendix

D.

TYPICAL

GOVERNMENT

PROVIDED

TRANSDUCERS

txJ g -J w <•< o

-J

o

>

o'

d

crLJ

o

o

Q

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go

e

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cj

60

•f4 o

UJ

<S> Z

UJ

c

<

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A3-17
-n

cz

Tt

3=

N>

A3-18

Appendix

D

(continued)

Integrated

Output

from

TurbineFlowmeter
Appendix D

(continued)

Integrated

Watts

(Watthours

<n

tuOO>od

oo

_j rc < 3 S O o m

{—K f— O <'4 0- >

cc° XO a H \
Appendix D

ntinued)

Venturi

Flowmoter,

Temperature

and

Diflorcntlal

Tamporatures

o:ljH

-id

Cl ^ hHOg

LlS > uuH3

UJ

a:5

a:UJ

a. o 5 £ UJ < 5-

L»J O<O>od zoH

C£o

CLo

££a. 8 IoH

-I< UJ

LU 2 £C o o O < 2 c/> H H </> JKUJ d § o Q CL H

J-Z us

UJ 1 cr =f

uj cu

u.

U. Z 5 2 o ^ O 2 pO 5? z o 7 a: P £ 2 . Q

£§O o

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Llx

g

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A3-20
APPENDIX 4: Venturi Flow Calibration Report

A4

The Foxboro Company FoxbOfO, Massachusetts, USA 02035 * Telephone (617) 543-8750

Flow Calibration Report

FCR72-150R

For

6-Inch Size Vickery-Simms , Inc. Model FFM Short Form Venturi Meter

Serial Number V6-362

Nominal Pipe Internal Diameter: 6.065“

Venturi Throat Diameter: 4.109"

Beta Ratio 0.6774

The Foxboro Company Fluid Flow Laboratory

Foxboro, Massachusetts

On

January 8, 1973

Using

Water at Ambient Temperature

Customer: Vickery-Simms , Inc.

Arlington, Texas

Customer Order Number: 0973, Job 7259

Foxboro Sales Order: 72N-46317

Cross Reference: National Bureau of Standards

Tested At

Gaithersburg, Maryland

Contract Number 2-35917

Report

Flow Engineering Department

Richard W. Miller

Manager, Flow Engineering Department

FoxborQ

J

A4-

1
^ CD

y i! < 6 s—1 O »-i

) 39BVHDSI0 JO INJIOIJJjm

A4-2

§

o

X

10

D

=

BORE

REYNOLDS

NUMBER
VENTURI

TUBE

FITTED

LINE

OF

REGRESSION

FOR

COEFFICIENT

OF

DISCHARGE

VS

BORE

REYNOLDS

NUMBER

A4-3

X

10°

=

BORE

REYNOLDS

NUMBER
Sheet 1

FLU* ENGINEERING DEPARTMENT REPORT NO. FCR72-150

V I CK.ERY-S I MMS , INC. FFM SHORT FORM VENTURI METER S/N Vb-362

IDENT IF ICAI ION NUMBER 327, REFERENCE DRAWING S-7259-1

METER CALIBRATION BY I HE MANOMETER METHOD

BASIC PORE D I A = 4 .1090 IN . BASIC PIPE D I A= 6.0650 IN. BETA = 0.6774

now FLUID, FL ( 1 ) = WATER F L ! 2 ) = SPINESSO 34 < FORMULA 1L23) OIL

mano fluid. MF ( 1 ) = MERCURY MF ( 2

)

=2.95 SP GR OIL MF ! 3 ) = 1 . 75 SP GR OIL

OBSERVED DATA

.A. “T- 2 3 4 5 6 7 8 9

RUN TARE wT FLOW FLOW MANOMETER TEST TIME GROSS WT MANO AVE

NO. POUNDS FLUID DEG F FLUID DEG F SECONDS POUNDS IN. WET

I 0.0 F L ( 1

)

71.2 MF 11 ) 74.8 100.860 14541.5 7.606

2 14541.5 FL( n 71.4 MF ( 1

)

74.9 101.210 37330.0 18.476

3 0.0 FLU) 71.4 MFU) 74.9 101.124 33019.5 38.655

4 0.0 FLU) 71.5 MF ( 1

)

75.1 101.077 32746.0 37.983

5 0.0 FLU) 71.5 MF( 3) 74.8 100.063 2984.

1

5.40 1 6 2904. 1 FLU) 71.5 MF! 3) 75.0 101.099 6330.5 6.661

7 0.0 FLU) 71.5 MF ( 3

)

75.0 101.340 3849.9 8.840

8 3849.9 FLU) 71.5 MF( 3) 75.0 101.130 8402.3 12.446

9 0.0 FLU) 71.8 MF (3) 75.0 100.903 5215.2 16.419

IU 0.0 FLU) 71.8 MF C 3

)

75.2 101.414 6360.5 24.261

1 1 0.0 FLU) 71.9 MF ( 3) 75.4 101.057 7496.2 33.900

12 0.0 FLU) 72.0 MF! 3) 75.5 101.191 8700.9 45.658

13 0.0 FLU) 72.0 MF l 3) 75.6 105.892 10395.0 59.578

14 0.0 FL(1) 72.0 MF ( 3) 75.7 100.851 3087.1 5.724

15 0.0 FLU) 72.0 MF! 3) 75.8 106.444 10443.0 59.481

DATE 1/8/73

M-4
Sheet 2

FLOW ENGINEERING DEPARTMENT REPORT NO. FCR72-150

VICKERY-SIMMS, INC. FFM SHORT FORM VENTURI METER S/N V6-362

IDENTIFICATION NUMBER 327, REFERENCE DRAWING S-7259-1

METER CALIBRATION BY THE MANOMETER METHOD

F.ASIC BORE D I A= A. 1090 IN. BASIC PIPE DIA= 6.0650 IN. BETA=0.6774

COMPUTED RESULT

* 11 12 13

RUN REYNOLDS-NUMBER COEFT-.

nc . BORE PIPE K

i 833408. 564628. 1.11134

2 1305069. 884176. 1.11364

3 1892594. 1282220. 1.11653

4 1880326. 1273909. 1.11757

5 173088. 117266. 1.12314

6 192113. 130155. 1.12092

7 220493. 149383. 1.11841

8 261266. 177008. 1.11665

9 301196. 204058. 1.11649

10 365490. 247617. 1.11463

1 1 432853. 293255. 1 .11530

12 502426. 340390. 1.1 14C4

1 3 573603. 388612. 1.11344

14 178663. 121178. 1.12011

15 573263. 388382. 1.11375

VtL CF APPROACH FACTCR=1..12557

REYNOLDS NO CGEF.= 3751.3

14 15 16

COEFF. US GPM AT PIPE VEL

C FLOW TEMP FT/SEC

0.98735 1039.78 11.54

0.98940 1623. 89 18.03

0.99196 2354.95 26.15

0.99289 2336.56 25.94

0.99784 215.08 2.38

0.99587 238.72 2.65

0.99364 273.99 3.04

0.99225 324.66 3.60

0.99193 372.78 4. 13

0.99028 452.35 5.02

0.99087 535.01 5.94

0.98975 620. 18 6.88

0.98922 708.04 7.86

0.99515 220.78 2.45

0.98949 707.62 7.e5

GEOGRAPHICAL METER COEF. = 0.83131

DATE i/8/73

A4-5
Sheet 3

FLOW ENGINEERING DEPARTMENT REPORT NG.FCR72-150

VICKERY-SIMMS, INC. FFM SHORT FORM VENTURI METER S/N V6-362

IDENTIFICATION NUMBER 327, REFERENCE DRAWING S-7259-1

METER CALIBRATION BY THE MANOMETER METHOD

bASIC BORE U I A= A. 1090 I;. BASIC PIPE D I A = 6.0650 IN. BETA=U.6774

COMPUTED RESULTS AND STATISTICAL ANALYSIS

I HE LEAST SQUARE LINE FOR C VERSUS! BORE REYNOLDS NUMBER )**(-!. 00)

C ! L E AST SQ) = 0.122374E 04MB0RE REYNOLDS NUMBER ) ** ( - 1 . 00 ) +0 . 988 A 5

K {LEAST SQ) = Q.933188E 03*(P1PE REYNOLDS NUMBER ) ** { - I . 00 ) +1 . 1 1 2 5

7

17 18 19 20 21

R 0 N REYNOLDS NU BORE REYNOLDS COEFF OF C COM- PC DEV C

NO. IN BORE, ROB N0**(-1.00) DISCHARGE PUTED TO LINE

5 173088. 0. 5777416-05 0.99784 0.99552 0.233

IA 178863. 0. 559088E-05 0.99515 0.99529 -0.014

6 192113. 0 • 520526E-05 0.99537 0.99482 0.105

/ 220A93. 0.453528E-05 0.99364 0.99400 -0.036

6 261268. 0 • 3827A8E-05 0,99225 0.99313 -0.088

9 301196. 0. 332010E-05 0.99193 0.99251 -0.058

10 365A90. 0.273605E-05 0.99028 0.99180 -0.153

1 1 432653. 0 . 23 1025E-05 0.99087 0.99128 -0.040

12 502426. 0. 199034E-05 0.98975 0.99088 -0.114

15 573263. 0. 17A440E-05 0.98949 0.99058 -0.110

13 573603. 0. 174336E-05 0.98922 0.99058 -0.137

1 833408

0. 119989E-05 0.98735 0.98992 -0.259

2 1 305069. 0. 7662AAE-06 0.98940 0.98939 0.001

A 1880326. 0. 531823E-C6 0.99289 0.98910 0.38 3

3 1 892 594

0.528376E-06 0.99196 0.98910 0.290

ERROR OF ESTIMATE = 0.00176 PERCENT ERROR OF ESTIMATE = 0.178

A4-6
NBS-114A (REV. 7-73)

U.S. DEPT. OF COMM. BIBLIOGRAPHIC DATA

SHEET

1. PUBLIC A'l'ION OR REPORT NO. NBSIR 79-1709

2. Gov’t Accession

No.

3. Recipient’s Accession No.

4. title: and subtitle:

Description of the Data Acquisition and Instrumentation

Systems: Jersey City Total Energy Project

5. Publication Date

6. Performing Organization Code

7. AUTHOR(S)

Charles Bulik, William G. Rippey, C.W. Hurley, Dan E. Rorrer

8. Performing Organ. Report No.

9. PERFORMING ORGANIZATION NAME AND ADDRESS

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COMMERCE

WASHINGTON, D.C. 20234

10. Pro ject/Task/Work Unit No. 4626382

11. Contract /Grant No.

12. Sponsoring Organization Name and Complete Address (Street, City, State, ZIP)

Department of Housing and Urban Development (HUD)

Division of Energy Building Technology and Research

Washington, D.C. 20410

13. Type of Report & Period Covered

14. Sponsoring Agency Code

15. SUPPLEMENTARY NOTES

ABSTRACT (A 200-word or less factual summary of most significant information. If document includes a significant

bibliography or literature survey, mention it here.)

Under the sponsorship of the Department of Housing and Urban Development (HUD) , the

National Bureau of Standards (NBS) gathered engineering data on an operating diesel

total energy plant which supplies all electrical power, hot water, and chilled

water to a 485 unit apartment/commercial building complex in Jersey City, New Jersey.

Engineering data was continously collected from April 1975 to December 1978 by a data acquisition system (DAS) which recorded the outputs from approximately 200 sensors located in the plant and site buildings.

This report describes the design and operation of the instrumentation system and

the data acquisition system used to monitor the total energy plant and certain

utility services to the site buildings. The report contains a description of the

types, characteristics and locations of instruments used to measure physical

variables. The capabilities and operational modes of the data acquisition system

components are described in detail. The report also contains a brief description

of the total energy plant and site, instrument costs, data processing procedures

and some of the instrumentation problems encountered.

17. KEY WORDS (six to twelve entries; alphabetical order; capitalize only the first letter of the first key word unless a proper name; separated by semicolons)

Data acquisition system; Digital tape recorder; Fuel measurement; Instrumentation;

Total energy; Transducers; Weather station

18. AVAILABILITY | | Unlimited 19. SECURITY CLASS 21. NO. OF PAGES

(THIS REPORT)

[

1 E or Official Distribution. Do Not Release to NTIS

UNCL ASSIF1ED

| J Order From Sup. of Doc., U.S. Government Printing Office Washington, D.C. 20402. SD Cat. No. Cll

20. SECURITY CLASS

(THIS PAGE)

22. Price

[

1 Order E rom National Technical Information Service (NTIS)

Springfield, Virginia 22151 UNCLASSIFIED

USCOMM-DC 29042-P74


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