Background Summary
The Houston Airport System (HAS) engaged Shipcom to investigate HVAC and environmental challenges at EFD and IAH airports, including elevated humidity, condensation, and airflow issues.
Installation was successfully completed on October 1st and 2nd at both EFD and IAH, with both deployments completed ahead of schedule. The EFD installation, including the site visit, took 4 hours, while the IAH installation, including the site visit, installation, and movement between terminals, took 5 hours.
The following sections summarize the issues identified at the EFD and IAH facilities and the recommended solutions. They also provide an overview of the sensors installed and their data feed into the Catamaran NextGen™ platform. An appendix presents detailed findings based on real-time data collected from the wireless IoT Smart Sensors.
42 Sensors
3 Gateways
2 Airports
9 Hrs
EFD
Problem
A suspected mechanical issue in the PPG maintenance facility was investigated, but findings showed HVAC 1 was functioning as expected. The primary issue was high humidity in the plenum space, causing water accumulation, mold, and damaged ceiling tiles that posed health concerns. The issue had persisted for three years and required three remediation efforts in the past year, resulting in significant costs and operational inefficiencies.
Introduce conditioned airflow into the plenum space to reduce temperature and humidity. Adjust return-air access points to draw air from the plenum, improving circulation and reducing stagnant airflow.
IAH
Problem
At APM Skyway Platform D, condensation on supply duct grates was creating a slip-and-fall risk as water dripped onto the platform. Limited air circulation and low static pressure allowed hot, humid outdoor air to enter the train landing area, causing passenger discomfort.
Verify CFM and static pressure levels to improve platform-level air circulation. Increasing static pressure and airflow can reduce outdoor air infiltration, duct surface temperatures, and ambient humidity—helping prevent condensation at the discharge grates. Once airflow and pressure are optimized, supply-air temperatures can be adjusted to maintain a reliable balance and avoid condensation.
Timelines & Milestone
OCTOBER 1ST
EFD Airport
14 Sensors
1 Gateways
Challenge:
High humidity in plenum space causing severe condensation and water build up, resulting in mold growth in the east section of the building.
Michael Wagoner noted that the tiles and insulation had been replaced at least three times in the past 10 months. Keep in mind the difference in function and build material between the east and west portion of the facility.
- 1 ambient temperature
- 1 ambient humidity
- 1 ambient humidity
- 1 ambient temperature
- 1 ambient humidity
- 1 supply air temp
- 1 return air temp
- 1 return air humidity
- 1 condenser amperage
- 1 blower amperage
- 1 supply air temp
- 1 return air temp
- 1 condenser amperage
- 1 blower amperage
Challenge:
Due to condensation issues at the discharge grate, causing puddles on the ground, the AHU has been turned off. This causes high temperatures on the APM platform at Terminal D.
- 1 return (outside natural) air temp
- 1 post cooling coil air temperature
- 1 supply air temperature (post reheat coil)
- 1 blower amperage
- 1 return (outside natural) air temp
- 1 post cooling coil air temperature
- 1 supply air temperature (post reheat coil)
- 1 blower amperage
- 1 blower amperage
- 1 ambient temperature
- 1 ambient humidity
- 1 return air temp
- 1 return air humidity
- 1 post cooling coil air temperature
- 1 blower amperage
- 1 chilled water temp
- 1 return air temp
- 1 return air humidity
- 1 post cooling coil air temperature
- 1 blower amperage
- 1 chilled water temp
- 2 ambient temperature
- 2 humidity sensors
- 2 discharge temperature
- 1 ambient temperature
- 1 ambient humidity
Catamaran NextGen™ Smart Airport Application
The following are a few screen-shots showcasing the live Shipcom application as the Smart Sensors are feeding real-time data to monitor and alert issues at both EFD and IAH.
OCTOBER 1ST
EFD Airport
Technical Findings
Detailed review of the mechanical data trends indicates that HVAC 1 is able to meet load requirements. The unit is producing an appropriate 20°F △T and the control mechanism is demonstrating the ability to cycle off at satisfaction.
In addition, HVAC 1 demonstrates enough capacity to affectively control humidity within the office spaces. This is proved in the chart below that even though the outdoor ambient humidity is high, the indoor humidity levels are controlled around 70% RH
As shown above, the lack of airflow within the plenum space allows temperature and humidity levels to rise mirroring outdoor ambient humidity levels. This is not ideal as the plenum humidity should be controlled (such as the yellow line). Introduction of much colder supply duct surface within this high humidity, high temperature environment results in significant condensation, water accumulation (saturation of insulation), ultimately growth of significant mold on all damp surfaces, such as the ceiling tiles.
Technical Findings
Terminal D’s APM platform HVAC system generated condensation issues at the supply air discharge points on the platform, causing slip and fall conditions for passengers. Due to this, the ambient temperature and humidity upon arrival/departure at the APM platform is extremely warm and muggy. Note that the Terminal A APM readings are control data as seen below.
The dark blue line, at Terminal A, indicates a very stable ambient temperature for passengers averaging at 70°F. It appears the climatization of Terminal D seems inactive. This is apparent since the pink, orange, and red lines, which represent the ambient temperatures on Platform D, are not indicating a stable maintained temperature, even though discharge air is coming out of the vents (blue line). Although, the supply air temperature (blue line) is not significant enough to cool the space.
In conclusion, from the sensors we have placed, we can now offer to HAS staff real time trending of ambient dew point conditions which can easily be matched to the surface temperatures of the discharge grates allowing for evaluation and adjustments to improve and maintain comfortable platform temperatures
As seen, the discharge surface temperature is 67.1°F and dew point is 69°F. By definition, the ambient temperature must be lower than the dew point to initiate condensation. Therefore, we believe by trending incremental operation changes resulting in lower supply air temperatures, we can assist in properly balancing a comfortable temperature without generating condensation. This will improve the comfort level of passengers while maintaining a safe environment.
Next Step
The next step is to understand the capabilities of the control mechanism, to achieve incremental changes. The AHUs in platform D have the capability to function properly, but their operations are so restricted that they cannot achieve reasonable satisfaction temperatures. We must further investigate with the maintenance team at Terminal D.
In addition, the graph below showcases how much is being spent while not achieving comfortable levels.
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