The Pharmaceutical Research Institute in La Jolla, California building are systems for limiting energy waste associated with its 92 fume hoods and its air handling

contents

The Pharmaceutical Research Institute in La Jolla, California, is a

123,000-square-foot laboratory and office building completed in

1999. Among the energy efficiency measures included in the

building are systems for limiting energy waste associated with its

92 fume hoods and its air handling, space conditioning, and light-

ing systems. As a result, smaller-than-usual chillers and fans were

employed, which both saved on first costs and will lower energy

bills over the life of the building. Despite employing the most

energy-efficient motors and other equipment available, the build-

ing cost only 1 percent more than other new laboratory/office

facilities built to the minimum requirements of California’s Title 24

energy standards.

Johnson & Johnson has over 250 business campuses worldwide,

and the company has made a commitment to aggressively pursue

energy efficiency wherever it makes sense. All new J&J buildings

are subject to the company’s “New Facilities Design Criteria.”

Design teams are required to adopt the energy efficiency mea-

sures specified or make a persuasive case for exceptions.

This “design for the long term” philosophy was successfully

employed in the design and construction of the Pharmaceutical

Research Institute facility. In addition to housing state-of-the-art

biological and chemical laboratories, the building is quite com-

fortable and attractive. It thus serves as a catalyst in recruiting new

scientific talent.

building case study

energy

design

resources

Introduction

The Building Program

The Design Process

Overview of the PRI Facility’s

Energy Efficiency Features

HVAC Systems

Laboratory Fume Hoods

Water Conservation

What Didn’t Make the

Cut? (And Why?)

What Should Have Made the Cut? 31

Conclusions

Appendix: Details from J&J’s New

Facility Design Criteria

biotech lab and office

The R.W. Johnson Pharmaceutical

Research Institute

pg_0002

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

The R. W. Johnson Pharmaceutical Research Institute (PRI), owned by

Johnson & Johnson (J&J) and located in La Jolla, California, is a state-of-

the-art, 123,000-square-foot research and office facility completed in 1999

(Figure 1). Only a mile from the Pacific Ocean, the building functions

well, provides a comfortable working environment for hundreds of biolo-

gists and chemists, and is aesthetically appealing. However, its energy bills

are a fraction of what a standard structure built to meet California’s Title

24 Energy Efficiency Standards would be, yet it cost no more than ordi-

nary structures of its kind to build.

J&J, which operates more than 250 facilities the world over, has a strong

corporate commitment to building structures that are energy efficient,

long-lasting, and inexpensive to maintain. Accordingly, the company has

developed an energy efficiency document titled “New Facility Design

Criteria.” Expressed in an easy-to-use spreadsheet, the design criteria

address all energy-relevant elements of new building design in careful

detail. Architectural and engineering firms that produce facilities for J&J are

PRI’s energy bills are a frac-

tion of what a standard

structure merely built to

meet California’s Title 24

Energy Efficiency Standards

would be, yet it cost little

more than ordinary struc-

tures of its kind to build.

Photos courtesy of Financial Times Energy

The PRI facility exterior

Figure 1:

The front exterior of the PRI facility balances functionality and aesthetics with elements that

convey a sense of permanence, such as beautiful stone facades.

pg_0003

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

charged with developing building designs that are consistent with the

“New Facility Design Criteria”—or to make a case for specific exceptions.

The default is to do things in accordance with J&J’s doctrine.

At the beginning of the building design process, the team hired by J&J

specified a number of features typical of standard practice, speculatively

developed research and development buildings in the fast-growing indus-

trial area of La Jolla. However, when they found that J&J “is in it for the

long term,” as Thornton Lewis, J&J’s project manager, puts it, “The design

firm became very positive about adopting our long-term view.”

The long-term view involved careful computer modeling of the entire

structure and weighting each building system element, both as a whole

and in part, for lifetime cost. The result is a facility that employs premium

efficiency motors, energy efficient lighting, a zoning strategy that limits sin-

gle-pass ventilation to only laboratory areas that really need it, occupancy

sensors for lights and fume hoods, and a host of other energy-saving

strategies. Since the above measures lower space conditioning energy

needs, much smaller than usual HVAC equipment is employed, and the

money saved substantially offsets additional expenses for the other ener-

gy efficiency measures.

Scientists and office personnel, as well as the person who was slated to

become head of maintenance of the new structure, were part of the design

process from the beginning (Figure 2, next page). This element of stake-

holder buy-in contributed substantially to producing a facility that capably

meets users’ needs. Further, the commissioning process—begun five

months prior to occupancy as systems came on line—ensured that glitch-

es were handled well before they became real problems and that training

of the maintenance team was thorough.

The building achieves annual savings of $536,000 on its energy bill, com-

pared to the amount a standard laboratory would expect to pay. According

to a model used to estimate energy performance of new buildings

employed by the local utility, San Diego Gas and Electric (SDG&E), a stan-

dard building would have used $1,432,000 per year, 37 percent more than

“The design firm became

very positive about adopt-

ing our long-term view.”

—Thornton Lewis

Johnson & Johnson

pg_0004

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

the J&J building. Based upon its exemplary energy performance, the build-

ing owners were awarded $143,000 for their inventiveness from SDG&E.

The PRI laboratory and office facility project was conceived by J&J to

replace a leased facility in the area that was used as a biology lab for the

previous 10 years. With the lease coming to an end, as well as a need to

expand the facility to accommodate more chemists and biologists, J&J

decided to build a new facility designed from the ground up to best meet

present and future needs (Figures 3 and 4). J&J started planning the pro-

ject in November of 1996, with the goal of moving workers into a fully

functional facility in mid-1999.

The building program called for space to accommodate about 250 occu-

pants, with the vast majority being scientists. The facility needed to sup-

port the wide variety of the scientists’ experiments, many of which take

place over an extended period and cannot be interrupted. The desire of

PRI maintenance team involved in the design process from the beginning

Figure 2:

Improved maintainability was achieved by involving the PRI maintenance team in the

design of key building systems. Pictured is facilities manager Steve Schuetzle.

pg_0005

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Overhangs and setbacks reduce solar gain

F igure 3:

A climate-responsive building envelope reduces the need for heating and cooling at PRI.

An inviting and eff icient facility

F igure 4:

Natural and artificial light work together to illuminate the PRI lobby.

pg_0006

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

many scientists to work at any hour of the day or night required building

systems designed to accommodate diverse usage patterns.

Clearly, the laboratory spaces had to be the dominant feature of the build-

ing from both the standpoint of space planning and building system

design. The program called for 92, 8-foot-wide fume hoods to be installed

to support scientific research (Figure 5). The energy use and complexity

of the mechanical systems to support the hoods was a priority building

system the design team needed to accommodate.

The differing safety requirements for chemists and biologists also were a

major consideration. Chemists tend to deal with harsher chemicals and

thus prefer smaller, enclosed laboratory spaces that serve as a barrier to

help contain fumes from their experiments. The biologists, on the other

hand, do not usually work with extremely hazardous materials. They pre-

fer to work in more open spaces.

The project was also subject to some strict constraints on the form of the

building. Because of local building codes, there was a height limit imposed

The desire of many scien-

tists to work at any hour of

the day or night required

building systems designed

to accommodate diverse

usage patterns.

Laboratory mechanical systems are the centerpiece of PRI

Figure 5:

The 92 chemical fume hoods included in the PRI facility substantially impacted the

architectural, mechanical, and electrical design.

pg_0007

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

for the building. Code mandated that no part of the building could extend

more than 30 feet above grade level. This was particularly troublesome for

a laboratory building because traditional fume hood exhaust stacks rise 6

to 8 feet above the roofline in order to safely eject fumes away from the

building. Subtracting the stack height from the 30-foot allowance left an

insufficient amount of floor-to-floor height for a two-story structure, which

was a strongly favored building configuration.

The project also had other issues to deal with. In particular, the cost and

availability of potable water in San Diego was a concern—even though

water is available, conservation is a big issue in San Diego. J&J wanted to

be a good citizen when dealing with water issues, so company officials

made a commitment to consider using municipal reclaimed water and

water from building condensate whenever it could be justified. Thus, they

were able to save about 10 percent on water costs, and at the same time

demonstrate their commitment to environmental stewardship.

The design of the PRI facility exemplifies the practical application of an

integrated design process. Maximizing energy efficiency of the building as

a whole—as opposed to focusing on the efficiency of individual building

systems—was a goal established early on in the project.

Johnson & Johnson has had a formal energy program in place since 1972.

Conceived during the Arab oil embargo, J&J’s cumulative energy design

wisdom is collected in a best practices document that offers recommended

energy design guidelines for all major building systems. This repository of

design wisdom has been continually refined and updated over the years,

and the cost-effectiveness of most of its recommendations is time-tested

and well documented.

Although it may sound restrictive, J&J’s best practices document still

leaves plenty of freedom for the design team. “We establish guidelines, as

opposed to rigorous requirements,” notes John Mohn III, PE, J&J’s site

project manager. J&J does not force design professionals to implement

every item in the best practices document, although it is the design team’s

Maximizing energy efficiency

of the building as a whole—

as opposed to focusing on

the efficiency of individual

building systems—was a

goal established early on in

the project.

pg_0008

responsibility to make the case that a particular item is NOT cost-effec-

tive or should not be implemented for other reasons.

J&J also approaches cost-effectiveness questions from the standpoint of

life-cycle cost, instead of merely the simple payback for a particular build-

ing upgrade. Because J&J plans to stay in business for a long time—and

because it will be its own tenant at the PRI facility for the foreseeable

future—company officials base their decisions on the total benefit offered

by particular energy upgrades, not just how quickly they recover their

incremental investment.

The design team was selected based upon proven track records of deliv-

ering efficient design solutions for high technology buildings. The archi-

tectural firm for the project, Carrier Johnson of San Diego, was selected in

mid-1997. Carrier Johnson, in turn, brought in Bechard Long Associates of

San Diego to provide mechanical, electrical, plumbing, and HVAC control

system design services.

To get the design process off to a good start, J&J met with the PRI design

team early in the schematic design phase to conduct an initial screening

of each item in the J&J design guidelines. Using rule-of-thumb analysis,

they were able to get a preliminary indication of which measures would

pay off and which ones could not be justified. “We eventually ended up

with three categories of measures,” notes Lewis. “There were a number of

no-brainer measures that we absolutely planned to implement, and then

there was a second group of measures that appeared to be cost-effective,

but which would require more detailed analysis to make an informed deci-

sion. Finally, there were those that did not stand up to even the first-cut

screening, and were clearly not cost-effective for this facility.” High effi-

ciency illumination sources and indirect lighting fixtures were among the

first of the no-brainer items, which also included premium efficiency

motors, primary and secondary chilled water pumping systems, and

enthalpy-controlled air-side economizers. The list of measures that

required further study, however, was more extensive. Some of the mea-

sures that were studied in greater detail included:

Because J&J plans to stay in

business for a long time,

company officials base their

decisions on the total bene-

fit offered by particular ener-

gy upgrades, not just how

quickly they recover their

incremental investment.

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0009

Purchasing electric power at primary voltage (12,000 volts)

Single- versus dual-glazed windows and low-emissivity glazing.

Thermal energy storage

Air distribution: 100 percent outside air for lab spaces only, or for the

entire facility?

Variable-speed drives on pump and fan motors

Most of these measures were evaluated with a computer-based energy

model of the proposed facility. The mechanical engineers for the project

developed an energy model to quantify the benefits of the proposed effi-

ciency measures. This model allowed J&J to accurately assess how cer-

tain measures, such as dual-pane glazing, might reduce heating and cool-

ing loads and therefore the size of HVAC equipment installed to serve

those loads.

J&J also takes a real-world approach to accounting for facility operating

costs. Whereas many organizations allocate energy and maintenance

costs from separate budgets and have difficulty dealing with measures

that save in one category but cost more in the other, J&J budgets the two

together. This allows them to account for, as an example, the fact that T5

lamps provide energy savings and good light quality but cost more than

common T8 lamps. Many organizations—school districts are an exam-

ple—shy away from implementing energy efficiency measures that may

result in increased maintenance costs, even if net operating cost savings

result, because they will not have a sufficient maintenance budget for

upkeep of the systems. By taking a look at the big picture, J&J is able to

succeed at reducing total operational costs, as opposed to energy costs

alone.

As the project team created their first schematic design package, they

aimed at meeting rigid, low-budget criteria. J&J found that some budget-

driven building features were not consistent with their best practices

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Whereas many organizations

allocate energy and mainte-

nance costs from separate

budgets and have difficulty

dealing with measures that

save in one category but cost

more in the other, J&J bud-

gets the two together.

pg_0010

guidelines. The early design schematic included the following energy-inef-

ficient features:

Incandescent lights in some spaces

Single pane windows

Chillers with standard efficiency, part-load performance.

“Energy efficient” instead of “premium efficiency” motors

Multiple motors on cooling tower fans in lieu of variable speed drives

J&J officials concluded that many of these features were standard practice

for similar buildings in the area. San Diego is a hotbed of the burgeoning

biotechnology industry, and La Jolla is considered to be a “Park Avenue”

address for biotech start-up companies. Such companies are usually fund-

ed by venture capital and have a high mortality rate that is largely tied to

whether they can successfully bring a product to market or obtain mean-

ingful patents before the funding runs out. Thanks to these financial and

temporal demons, most start-ups lease their office space on the basis of

low cost and immediate availability as opposed to long-term efficiency.

Thus, it follows that most research-oriented buildings for lease around the

PRI site are developed to cater to short-term needs and don’t include many

efficiency features. Once J&J’s long-term energy conservation mindset was

known, the design effort focused on energy-efficient, low maintenance

options.

Most architects and engineers are used to translating their clients’ (some-

times unrealistic) wishes into workable designs. In this case, the design

team was constantly challenged to produce “life-cycle effective” designs

by a savvy client with a wealth of corporate expertise.

J&J officials met with the design team to let them know that J&J is “in it

for the long term” and that they were sincere in their desire to follow the

corporate best practices to the greatest practical extent. With this affirma-

tion from the client, the design team went back to the boards to produce

an award-winning, energy-efficient building.

Most architects and engi-

neers are used to translating

their clients’(sometimes

unrealistic) wishes into

workable designs. In this

case, the design team was

constantly challenged to

produce "life-cycle effec-

tive" designs by a savvy

client with a wealth of cor-

porate expertise.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0011

J&J was diligent throughout the design process to ensure that the design was

as good as it could be. Through each step of the design process, and in

cooperation with end users and the design and construction team, officials

asked themselves again and again:

Do our best practices requirements make sense?

Do we meet the requirements?

Are we over- or under-designed?

Are there any new opportunities?

What are the costs and benefits of the alternatives?

With J&J’s support and through the skill of the design team, the final

design achieved an impressive level of efficiency and did so within the

overall project budget. With the construction manager brought on board

in the third quarter of 1997, J&J broke ground on the PRI in the first quar-

ter of 1998. About a year later, building systems were commissioned as

they came on line.

Rudolph & Sletten (of Foster City, California, and San Diego), general con-

tractor on the PRI project, teamed up with the engineer to implement a

fully documented commissioning procedure in which each building sys-

tem was rigorously tested by itself under all sequences of operation. Once

all systems were shown to properly function individually, the facility was

subjected to a 72-hour functional test with all building systems in opera-

tion. With the deficiencies addressed and the project completed, PRI

employees moved in over Memorial Day in 1999.

When all was said and done, the PRI building’s impressive list of energy

efficiency and water conservation features resulted in an annual savings of

more than a half million dollars. This translates into:

Enough electricity to power 680 homes

Enough natural gas to heat 950 homes

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

With J&J’s support and

through the skill of the

design team, the final

design achieved an impres-

sive level of efficiency and

did so within the overall

project budget.

pg_0012

Reduced power plant emissions of 4.8 tons of nitrogen oxides per year,

2.1 tons of sulfur oxides per year, and 4,318 tons of carbon dioxide per

year

’

Energy-conscious design principles were applied to nearly all of the build-

ing systems at the PRI facility. The design wisdom embodied in J&J’s best

practices and in its corporate expertise includes the following elements:

Before any HVAC system efficiency measures are consid-

ered, J&J first works hard to reduce HVAC loads through application of

internal and external load reduction measures. These include efficient light-

ing, high performance glazing, occupancy sensors, sash position sensors on

fume hoods, and appropriate insulation. In particular, the company desires

measures that not only save energy by themselves but that also result in

downstream savings.

With heating and cooling loads reduced, the

design process then focuses on efficient strategies for delivering heating

and cooling to the building. Systems efficiency measures include low-pres-

sure ductwork, variable speed drives, premium efficiency motors on fans,

and advanced controls. Rather than oversize the HVAC systems so that

they never work too hard to provide comfort, J&J advocates “right sizing”

systems so that they provide efficient operation during three seasons, and

occasionally operate flat-out to meet peak loads in the heat of summer.

This reduces the size and cost of HVAC equipment, producing dollar sav-

ings that can be spent on more efficient equipment.

With loads minimized and efficient systems in

place, the crosshairs target the efficiency of plant equipment. As a result

of the good work done in previous steps, high efficiency chillers and boil-

ers can be purchased for little or no incremental cost when compared to

oversized, average efficiency models.

Following is an overview of the most notable features of the building

systems.

Systems efficiency mea-

sures include low-pressure

ductwork, variable speed

drives, premium efficiency

motors on fans, and

advanced controls.

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0013

The building is constructed of steel framing and curtain

wall (Figure 6). The walls are insulated only to the prescriptive levels

required by Title 24 for the San Diego climate—R-11 for walls and R-19 for

the roof. Though higher insulation levels were evaluated, they did not pro-

vide much energy savings in the mild La Jolla climate. A white reflective cap

sheet was installed on the roof, which both reduces the overall cooling load

for the facility and extends roof life because of the reduced roof tempera-

ture. This measure had no incremental cost associated with it; it was simply

a matter of selecting a material that was light and reflective.

The team evaluated dual-pane glazing—as an upgrade for the entire

project—but found the measure was too expensive relative to the savings

it would provide. In a late-night project meeting, J&J realized that dual

glazing was not an all-or-nothing proposition. The engineers suggested

glazing options for different orientations of the building and for offices

with exposures in several directions. As a result, a revised analysis was

prepared that addressed glazing issues on each facade of the building.

This led J&J to the decision to use dual-pane glazing on the east facade in

order to control morning sunlight and single-pane glazing on the other

facades.

Like most buildings that reach an exemplary level

of energy efficiency, the PRI facility features a highly efficient interior light-

ing system. This is a critical component of the whole building’s efficiency,

for two reasons:

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

The PRI facility rear exterior

Figure 6:

The back of the PRI facility. The walls and roof are insulated to conform to Title 24’s

provisions. Higher levels of insulation were deemed unnecessary in La Jolla’s mild climate.

pg_0014

1. Lighting energy use is huge. Lighting is the single largest energy end

use in most commercial buildings (though perhaps not for a laborato-

ry facility), accounting for anywhere between 25 and 50 percent of

overall energy use. In addition, even though T8 lamps and electronic

ballasts are standard practice for new lighting designs in California

today, there are still opportunities to significantly improve lighting effi-

ciency through a combination of good design and efficient technology.

Even though California’s 1998 Title 24 lighting efficiency standards are

already fairly stringent, they can still be beat by 30 percent or more,

which may translate into a load reduction of 0.30 to 0.50 watts per

square foot.

2. Lighting efficiency leads to downstream savings. The ample load

reductions that result from efficient lighting lead to reduced cooling

loads as well. As a result of reduced cooling and airflow requirements,

a series of “downstream” savings are generated, including smaller

ductwork, piping, air-handling units, and chillers. All of these down-

stream efficiency gains translate into reduced operating cost, as well as

construction cost savings for the smaller systems.

The interior lighting system at the PRI facility is designed around high-qual-

ity fluorescent sources that are applied to balance efficiency with visual

comfort. Pendant-mounted, indirect fixtures using T5 lamps and electronic

ballasts are used in most office spaces (Figure 7) in order to provide a uni-

form, glare-free environment. By bouncing light off the ceiling instead of

shining it directly into the workspace, a uniform level of illumination is

achieved instead of the checkerboard of bright and dark spots that typical-

ly result from direct lighting. Bouncing light off the ceiling also diffuses it

effectively, reducing glare on computer screens.

T5 lamps are quite intense when compared to other linear fluorescent

sources and consequently have enough punch to illuminate a space with

fewer fixtures than a system designed around T8 lamp technology. Even

though T5 fixtures are more expensive than similar configuration T8 mod-

els, in most cases the reduced number of fixtures offsets much of this

extra cost.

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Even though T8 lamps and

electronic ballasts are stan-

dard practice for new light-

ing designs in California

today, there are still oppor-

tunities to significantly

improve lighting efficiency

through a combination of

good design and efficient

technology.

pg_0015

Traditional T8 lamps and electronic ballasts are employed in non-office

spaces. Compact fluorescent lamps installed in recessed fixtures are used

in some spaces as well. J&J proudly reports that, except for what is con-

tained in some specialized laboratory equipment, there is not a single

incandescent lamp used in the PRI facility.

Other noteworthy features of the lighting system include occupancy sen-

sors throughout the building and the use of radioactive (tritium) exit signs

that glow without a wired power source (Figure 8, next page). One main-

tenance worker noted that the energy savings for the exit signs are almost

inconsequential compared to the maintenance savings associated with not

having to replace ever-failing lamps.

Whereas using occupancy sensors in small, enclosed spaces is quite com-

mon in buildings today, J&J aggressively went after additional savings by

installing these devices in open office spaces, as well as in the usual pri-

vate offices, restrooms, and conference rooms. They report that the sen-

sors can work well in open spaces as long as the right technology is spec-

ified. Key design features that need to be matched include passive

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Indirect lighting balances comfort and eff iciency

Figure 7:

T5 lamps and electronic ballasts in pendant-mounted, indirect fixtures minimize glare by

bouncing light off the ceiling and then down to the occupants.

Even though T fixtures

are more expensive than

similar configuration T8

models, in most cases the

reduced number of fix-

tures offsets much of this

extra cost.

pg_0016

infrared, ultrasonic, or dual-technology sensors; configuration view angle

(the pattern that the sensor can “see”); and sensor placement (Figure 9).

J&J also addressed the efficiency of lighting at individual workstations by

providing T8 or T5 lamps for all task lighting.

Even though San Diego has a mild climate, heating or cooling is still need-

ed every month of the year. This is particularly true for a lab facility that

must be kept within a relatively narrow band of temperature and relative

humidity for experimental procedures.

Every laboratory in the building is designed as a “once-through” system that

brings in 100 percent outside air, runs it through the building to heat or cool

it, and then exhausts it all (Figure 10). This causes a lot of conditioned air

to be exhausted out of the building instead of being recirculated, resulting

in increased heating and cooling energy and higher energy cost. In response

to this, J&J decided to install a once-through system to serve laboratory

spaces and a recirculating system for office and administrative spaces. This

design minimizes energy waste by tailoring ventilation rates according to the

use of each space.

Most of the building is designed around single-duct variable air volume

(VAV) air handling systems, featuring central chilled water and hot water

Every laboratory in the

building is designed as a

“once through” system that

brings in 100 percent out-

side air, runs it through the

building to heat or cool it,

and then exhausts it all.

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Tritium exit signs provide safe signage without electricity

F igure 8:

These exit signs, which use a radioactive material as their illumination source, do not require

electrical power and last up to 20 years.

pg_0017

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Using occupancy sensors in open spaces provides substantial

energy savings

F igure 9:

Multiple, ceiling-mounted sensors with overlapping areas of coverage make it possible to

effectively control lighting in open spaces, such as this laboratory.

How air flow differs between laboratory and office

Figure 10:

Labs typically require two to three times the amount of air as in a standard office building,

but none of it is recirculated.

Typical office

Supply air

100%

Return air

100%

Typical lab

Source: Financial Times Energy

pg_0018

coils, and hot water reheat coils in each zone for individual temperature

control. The air handling units were fitted with variable speed drives

(VSDs) in order to reduce fan energy use during periods of mild weather.

The mechanical engineer used an energy model to evaluate permutations

of chiller quantity, type, and capacity before finally settling on two, 600-

ton centrifugal chillers, each fitted with a variable speed drive (Figure 11).

Even though installing a VSD on only one chiller could have saved some

initial cost, J&J decided to spend the extra money to put VSDs on both

chillers. Their rationale was that they wanted the efficiency and control

that the VSD affords regardless of which chiller runs at a given time. They

recognized that each chiller would need to be periodically taken off-line

for service, and they didn’t want to have to juggle maintenance schedules

to respond to anticipated cooling requirements. In addition, their approach

allows them to alternate which chiller comes on first, resulting in more bal-

Even though installing a VSD

on only one chiller could

have saved some initial

cost, J&J decided to spend

the extra money to put VSDs

on both chillers.

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Centrifugal chiller with variable speed drives

Figure 11:

This 600-ton, VSD-driven centrifugal chiller provides efficient operation under varying load

conditions.

pg_0019

anced wear-and-tear on the chillers over time. In practice, the two chillers

are alternatively assigned as the “lead” chiller on a weekly basis.

The chillers were also selected to operate reliably with low entering con-

denser water temperatures. This capability substantially improves chiller

efficiency during much of the year. To take full advantage of this feature,

the engineers generously sized the two cooling towers (Figure 12), and

also specified wetbulb temperature reset controls that measure the out-

door conditions and reset the condenser water temperature downward

when conditions permit.

Chilled water is circulated to the air handling units through a variable flow,

primary/secondary distribution system, with two-way throttling valves

installed on each cooling coil to reduce the flow rate when cooling loads

are small. VSDs are installed on the secondary chilled water pumps (Figure

13, next page), saving substantial energy during off-design conditions.

All fan and pump motors are premium efficiency (Figure 14, next page),

meaning that they are of the highest efficiency commercially available

within each horsepower category. Because electric motors consume many

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Induced-draft cooling towers provide efficient heat rejection

Figure 12:

Two induced-draft cooling towers provide heat rejection for the chillers. They were generously

sized in order to improve chiller operating efficiency over much of the year.

VSDs are installed on the

secondary chilled water

pumps, saving substantial

energy during off-design

conditions.

pg_0020

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Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Variable-speed chilled water pumps

Figure 13:

Each of the secondary chilled water pumps is fitted with a variable-speed drive, providing

substantial energy savings during light load conditions.

Premium efficiency motors

Figure 14:

Premium efficiency motors provide additional energy savings when used instead of motors

that merely meet the National Electrical Manufacturing Association’s “high efficiency” motor

efficiency requirements.

pg_0021

times their purchase price in energy over their lifetimes, J&J feels that it is

almost always cost-effective to purchase the highest efficiency available.

To ensure that they were getting the energy performance they paid for, J&J

specified that chillers and air handling units would undergo performance

testing at their respective points of manufacture, and that J&J would only

accept this equipment after its performance was witnessed and documented.

Recognizing the mild nature of the San Diego climate, boilers for space

heating were specified to have high efficiency, high turndown burners that

can efficiently meet a wide range of heating loads (Figure 15). In addi-

tion, flue stack economizers were installed that recover heat from the boil-

er exhaust air that is then used to preheat makeup water for the boilers.

The control of the HVAC system components is managed by a distributed

digital control (DDC) system. The system allows efficient equipment sched-

uling, as well as a wealth of energy saving sequences of operation such as

chilled water temperature reset and static pressure reset for fan systems. J&J

evaluated several comparable systems but ultimately decided on the prod-

uct that offered the greatest compatibility with hardware in other J&J facil-

ities and that their facility engineers were comfortable with using.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

High eff iciency space heating boilers

Figure 15:

High efficiency boilers with flue stack economizers (not visible) minimize energy use for

space heating.

Flue stack economizers

were installed that recov-

er heat from the boiler

exhaust air that is then

used to preheat make-up

water for the boilers.

pg_0022

To allow the chiller microprocessor-based control panels to communicate

with the DDC system that controls other building systems, J&J opted to

install communication gateways (Figure 16). These hardware devices

allow data sharing between devices that follow disparate communication

protocols, enabling enhanced chiller control and better integration with

the operation of other building systems.

Digital controls were used throughout the facility, including for the VAV

terminals that control the temperature in occupied spaces. Because these

distributed microprocessors are networked together, the facilities staff can

often troubleshoot comfort complaints from the PC in their office instead

of having to go to the physical location of the complaint.

One of the most conspicuous results of involving the maintenance staff in

the design of systems that they would eventually service is the amount of

open space around mechanical and electrical equipment. For example,

adequate clearance is given to easily pull the tube bundle out of each

chiller without tearing the room apart (Figure 17), or to set a new motor

without dismantling much of the surrounding piping. There is ample space

around air handlers to facilitate maintenance. This feature comes with a

price tag, though, because space taken up for mechanical and electrical

Digital controls were used

throughout the facility,

including for the VAV ter-

minals that control the

temperature in occupied

spaces.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Communication gateways facilitate inter-device communications

Figure 16:

The communication gateway (left) allows the chillers to communicate with the digital control

system (right two devices).

pg_0023

rooms means the building gets larger and more expensive. The benefit of

substantially enhanced maintainability of the systems, though, was felt to

be well worth the effort.

From the standpoint of financial savvy, J&J left its indelible mark in anoth-

er way. Because of the inherent efficiency of the various HVAC system

components—VSD motors, for example, are intrinsically “soft started” and

therefore significantly reduce inrush current—J&J was able to justify

downsizing the capacity of the emergency generator from 2,000 kilowatts

(kW) to 1,500 kW. This resulted in significant cost savings and also

reduced space requirements for the generator.

Even though the energy efficiency of laboratory fume hoods is not governed

by Title 24, J&J recognized that these were probably the single largest ener-

gy users in their proposed building. Fume hoods are directly responsible for

a large amount of fan energy, and they are indirectly responsible for vast

amounts of heating and cooling energy because of the volume of condi-

tioned air they continually exhaust from the labs. Accordingly, J&J worked

hard to make these systems as efficient as possible while maintaining a safe

and productive working environment (Figure 18).

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Chiller room

Figure 17:

Having adequate space to service large pieces of equipment such as chillers can save downtime

and expense.

Fume hoods are directly

responsible for a large

amount of fan energy, and

they are indirectly responsi-

ble for vast amounts of

heating and cooling energy

because of the volume of

conditioned air they contin-

ually exhaust from the labs.

pg_0024

J&J involved the scientists who would eventually occupy the PRI facility

extensively in the process of evaluating candidate laboratory mechanical

systems. In particular, the design team solicited input on the merits of

installing variable air volume fume hood controls instead of traditional

constant volume controls. Once the scientists learned about the enhanced

safety, reduced noise, and impressive energy savings that VAV hood con-

trols can provide, they cautiously endorsed this system but stated, “It had

better work.” J&J ultimately opted to install VAV fume hood controls in all

chemical fume hoods. Since they first occupied the building in mid-1999,

response from the scientists to these advanced fume hoods has been over-

whelmingly positive.

After the engineers evaluated the various product offerings on the market,

J&J opted to install VAV supply and exhaust valves that provide ultra-fast

response to changing conditions in the lab (such as a fume hood sash

being abruptly opened or closed). It also issues an audible alarm if safe

Johnson & Johnson involved

the scientists who would

eventually occupy the PRI

facility extensively in the

process of evaluating candi-

date laboratory mechanical

systems.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Laboratory fume hood

Figure 18:

The PRI facility includes 92 fume hoods.

pg_0025

conditions are not being met because of some sort of equipment failure in

the hood or downstream in the exhaust system (Figure 19).

One interesting feature is an occupancy sensor for each fume hood that

senses when somebody is in the vicinity of the hood. When no one is

around, the airflow velocity through the hood is reduced from its usual

value of about 100 feet per minute (fpm) down to 60 fpm. This reduction

saves fan energy, but more importantly reduces the amount of conditioned

air that is exhausted out of the building during periods of non-use. When

someone approaches the fume hood, the system senses their approach

and quickly kicks the face velocity back up to 100 fpm. Because many of

J&J’s scientists like to work at odd hours, there is a great diversity in the

use of most fume hoods. The usage-based controls capture much of the

savings potential of this diversity.

The exhaust and makeup air systems that serve spaces with fume hoods

are usually quite large when compared to traditional HVAC systems

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

VAV fume hood controls provide energy savings and enhance safety

Figure 19:

This fume hood controller sounds an alarm if it is not performing properly and lets users

know if it is operating in standard or standby mode.

When no one is around, the

airflow velocity through the

hood is reduced from its

usual value of about 100

feet per minute (fpm) down

to 60 fpm.

pg_0026

because of the large airflow requirements of fume hoods (Figure 20).

Installing VAV fume hoods that move less air when they are not used and

driving overall exhaust rates down further with the usage-based controls

allowed the mechanical engineer to make a case for downsizing other

mechanical systems (Figures 21 and 22). Because of the proposed sys-

tem’s ability to predictably respond to diverse use, J&J was able to install

ducts and fans that were about 25 percent smaller than they would be if

constant volume controls were installed. This also translated into smaller

chillers and boilers because of the reduced amount of conditioned air

exhausted from the building. These cost savings were used to offset the

higher cost of the VAV hood controls.

As mentioned previously, the PRI facility had a 30-foot height limitation

imposed by applicable local building codes. Accordingly, a conventional

fume hood exhaust extending 6 to 8 feet above the roofline would have

imposed serious limitations on the floor-to-floor heights for the proposed

two-story structure. To minimize the amount of vertical height that the

exhaust stacks would steal from the building, J&J opted to install high-

entrainment exhaust fans (Figure 23). These fans have an innovative

Because of the proposed

system’s ability to pre-

dictably respond to diverse

use, J&J was able to install

ducts and fans that were

about 25 percent smaller

than they would be if con-

stant volume controls were

installed.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Standards for Laboratory Exhaust Systems

There is some confusion about the governing stan-

dards for laboratory exhaust systems because a

number of organizations publish standards. The

most commonly cited standard is ANSI/AIHA Z9.5

(1992), developed by the American National

Standards Institute and the Association of Industrial

Hygienists of America. Other widely used stan-

dards include the Occupational Safety and Health

Administration 29 CFR, Part 1910; the National Fire

Protection Association Standard 45; and the

American Society of Heating, Refrigeration, and Air

Conditioning Engineers Standard 110, “Methods of

Testing Performance of Laboratory Fume Hoods.”

Although there are differences among them, most

of the standards are in basic agreement on the fol-

lowing performance requirements:

Maintain a face velocity of 100 feet per minute

with the sash in the open position.

Maintain a slightly negative pressure in the lab

with respect to adjoining corridors and offices to

create a secondary containment barrier.

Maintain a ventilation rate of 12 to 16 air changes

per hour while the lab is occupied.

pg_0027

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Source: Financial Times Energy

Exhaust stack

Reducing cone

Centrifugal fan

Roof

Fume hood exhaust

90° inlet

elbow

Flexible

connector

Typical centrifugal utility fan in fume hood exhaust

Figure 20:

The field-installed components, such as inlet elbows and flexible connectors, in the typical

fume hood exhaust system result in a large pressure drop that the fan must overcome in order

to produce the necessary exit velocities for the airstream.

Source: Financial Times Energy

Schematic of a variable-volume fume hood

Figure 21:

The constant-face-velocity controller gathers information from a velocity sensor positioned

inside the fume hood or from a sash position sensor. The sensor feeds information to the

controller, which adjusts the damper position to obtain the necessary airflow.

Single-blade

volume damper

Damper motor

Operator

display/control

panel

Constant-face-

velocity controller

Sash

position

sensor

Sash

Face

Velocity sensor (pitot tube)

pg_0028

design that produces a “virtual stack” that is much higher than their phys-

ical height. They accomplish this by mixing large quantities of outdoor air

with the fume-laden effluent from the fume hoods before it is blasted high

above the facility. The result is a tight exhaust plume directed away from

possible exposure that is quickly diluted by outside air.

Wanting to ensure that this advanced technology performed as published, J&J

commissioned Bechard Long and Associates to compile a mathematical

model for exhaust plume distribution. The goal was to have concentration of

no more than 1 part per million (ppm) in the event of accidental release of

a significant amount of chemicals. The highest concentration predicted by the

model at building air intakes or at any normally occupied location was about

0.5 ppm—far lower than J&J’s requirement for safety, and proof that the fans

perform as promised.

An additional, significant advantage of the fans was that their efficient design

led to an approximate 25 percent reduction in installed horsepower when

compared to typical fume hood exhaust stacks fitted with utility fans.

Since San Diego has no real potable water resources of its own, the city

takes an aggressive stance toward conservation of this precious resource.

As one water district authority staff member once put it, “San Diego is at

the end of a mighty long straw.” In other words, its water supply comes

from distant sources.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Venturi valve air flow regulator

Figure 22:

The adjustable cone that fits within the venturi valve in the fume hood air exhaust duct may

allow for more accurate adjustments in the rate of airflow than is possible with traditional

single-bladed dampers.

Airflow

pg_0029

J&J implemented a number of water conservation technologies at PRI.

These include:

Recovering condensate from cooling coils to use as make-up water for

the cooling towers. Even though this measure had a 15-year payback,

J&J felt that implementing this measure was consistent with their goal

of environmental stewardship.

Using reclaimed water for landscape irrigation and other uses (Figure

24, next page). Using reclaimed water (which is available through a

separate municipal water distribution system in the vicinity of PRI) for

landscape irrigation and for providing makeup water to the cooling

towers gave J&J a two-fold benefit. First, the reclaimed water costs

about 10 percent less than regular water. Second, making a commit-

ment to use it may give J&J some beneficial considerations if drought

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

High entrainment exhaust fans reduce stack height, safely exhaust fumes

Figure 23:

The configuration of these fans produces a virtual stack height that is far higher than their

actual height.

“San Diego is at the end of a

mighty long straw.”

—Water District

staff member

pg_0030

conditions ever necessitate serious curtailment of water use in the

future.

’

(

)

Because of the extensive list of energy efficiency features of the PRI facil-

ity, it may seem that no reasonable technological stone was left unturned.

This is not the case, though; a number of worthwhile design strategies

were considered but ultimately omitted for non-energy reasons.

Primary vs. secondary service voltage. The engineering team made an

analysis of utility cost saving that would result from installing an elec-

tric substation owned by J&J that would allow them to purchase elec-

tricity at a lower cost. Even though the potential cost savings were

impressive, it was ultimately decided that the reduced maintenance

requirements and overall issues of accountability favored buying elec-

tricity at the more expensive secondary service voltage. Under the

Using reclaimed water for

landscape irrigation and for

providing make-up water to

the cooling towers gave

Johnson & Johnson a two-

fold benefit.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Reclaimed water

Figure 24:

Reclaimed water is used for landscape irrigation at PRI.

pg_0031

lower voltage scenario, SDG&E owns and maintains the equipment that

steps voltage down from transmission to distribution levels. Since the

utility has sole accountability for getting power all the way to the PRI

facility service vault, J&J will not have to worry about operating and

maintaining an electric substation and can let the utility bring its exten-

sive experience to bear on this essential practice. This is especially

important when one considers the substantial financial losses embod-

ied in scientists who cannot work if there is a power interruption.

Thermal energy storage. The economics were favorable for installing a

thermal energy storage (TES) system that would inexpensively pro-

duce chilled water during non-peak utility cost periods such as the

middle of the night. However, the constrained project site made it dif-

ficult to find a suitable location for the large chilled water storage tank

that would be required. TES was ultimately ruled out because of a lack

of available space.

Hindsight is 20/20, and after a couple years of operation J&J allows that

there are a few features that they wish had been included in the original

design.

Install a pony chiller to serve light cooling loads. Even though the two

600-ton centrifugal water chillers are each fitted with variable speed

drives that allow them to efficiently serve fairly light cooling loads,

there is a small but constant cooling load that is too small for them to

serve reliably. The data center requires 20 to 30 tons of air condition-

ing on a 24/7 basis, and J&J had to install a couple of packaged direct

expansion (DX) cooling units to provide reliable cooling for this criti-

cal space.

Implement deeper tinting in some spaces to improve comfort. Some

perimeter office spaces had substantial glare problems because of

direct sunlight entering the space. To ameliorate visual conditions for

workers in such spaces, J&J installed a tinted solar control film to

reduce the intensity of glare. If they were doing it again, they would

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

Johnson & Johnson will not

have to worry about operat-

ing and maintaining an elec-

tric substation and can let

the utility bring its extensive

experience to bear on this

essential practice.

pg_0032

have evaluated additional fins or overhangs in the problematic spaces

to keep direct beam insolation off the glass in the first place.

Upgrade humidification system capacity. San Diego is a “binary” cli-

mate when it comes to humidity. Certain research spaces require that

humidity be maintained within reasonable tolerances, and, even

though San Diego is temperate and not too dry most of the time, it can

at times be quite arid. When Santa Ana winds reverse the coastal flow

and bring in hot, dry air from the deserts to the east, the relative

humidity can be extremely low. The humidification system at PRI was

not furnished with adequate water make up and an additional feed

had to be installed.

This is a short list of shortcomings for PRI, in light of the extensive list of

project successes. Nonetheless, J&J has learned useful lessons from these

minor shortcomings and has modified its best practices process to reflect

newly acquired practical wisdom.

All modern laboratory buildings are complicated affairs and it’s hard to

make them work right under the best of circumstances. The Pharmaceutical

Research Institute in La Jolla had to be constructed under a number of par-

ticularly stringent environmental constraints. Yet it works well, uses much

less energy than similar laboratory facilities, and is easy to maintain. The

building’s success depended on a combination of J&J’s design philosophy

(reflected in the company’s “New Facilities Design Criteria”), careful mod-

eling of building systems to envision how each works on its own and what

its impact is on the others, and a steadfast vision of the need to produce a

robust structure that will function well for many decades.

Going with the most efficient equipment possible made sense in almost

every case, for it will last longer, use less energy, and allow for HVAC

equipment to be smaller and less expensive. “Proper sizing is a key goal,”

observes Harry Kauffman, J&J’s corporate energy director, who is respon-

sible for the development of the “New Facilities Design Criteria.” “Most of

the time A&E firms use rule-of-thumb estimates for sizing equipment, but

modeling actual loads leads to much more accurate sizing.”

If they were doing it again,

they would have evaluated

additional fins or overhangs

in the problematic spaces to

keep direct beam insolation

off the glass in the first

place.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0033

Hardheaded cost-benefit studies were applied to every system in the

building, but common sense presided over the court of appeals. Most

often, common sense focused on the importance of reliability and smooth

operation over the long term. For example:

Both of the two large chillers had VSDs installed to facilitate mainte-

nance and provide flexibility with controls, though cost/benefit analy-

sis did not support this decision.

A condensate recycling system was installed in spite of showing a 15-

year payback because J&J wants to be a good corporate citizen. Using

reclaimed water provided cost savings, improved environmental per-

formance, and also reduces the chances that PRI will be shut off in the

case of a future water crisis.

The chiller room is oversized and arguably wastes valuable space. But

when major equipment must be serviced or replaced, the decision to

anticipate the need for extra space will be highly praised.

Making judicious use of practical design criteria, computer modeling, cost

benefit analysis, and the like helps in making good decisions on key ele-

ments of a building, but that’s only part of the design process. “One hun-

dred percent completion of best practices does not guarantee a cost-effec-

tive and energy efficient design,” Kauffman points out. “Parts must be inte-

grated to ensure a successful whole.”

The J&J building in La Jolla is a well-designed whole; it’s an attractive facil-

ity, inside and out. It’s also a pleasing and highly functional and comfort-

able facility to work in. Hence, it constitutes a non-trivial element in J&J’s

pursuit of top scientific talent.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

“One hundred percent com-

pletion of best practices

does not guarantee a cost-

effective and energy effi-

cient design. Parts must be

integrated to ensure a suc-

cessful whole.”

—Harry Kauffman

Johnson & Johnson

pg_0034

’

The following is a reproduction of key elements of J&J’s “New Facility

Design Criteria,” an in-house publication used in the design and construc-

tion of its facilities worldwide, including the La Jolla, California,

Pharmaceutical Research Institute, a state-of-the-art, 123,000-square-foot

research and office facility completed in 1999.

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0035

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0036

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0037

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0038

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0039

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0040

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0041

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0042

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0043

page

Building Case Study: R.W. Johnson Pharmaceutical Research Institute

pg_0044

Energy Design Resources provides information and design tools

to architects, engineers, lighting designers, and building owners

and developers. Energy Design Resources is funded by California

utility customers and administered by Pacific Gas and Electric

Company, San Diego Gas and Electric, and Southern California

Edison under the auspices of the California Public Utilities

Commission. To learn more about Energy Design Resources,

please visit our Web site at www.energydesignresources.com.

This design brief was prepared for Energy Design Resources by

Financial Times Energy, Inc., Boulder, Colorado.