ChallengeThe Hawaii Air National Guard outlined its criteria for a new

hanger/paint booth and support building facility to maintain

and repair its contingent of F-22 Raptor jets. The facility

would need to meet complex, exacting temperature and

humidity requirements in order to ensure process quality, and

due to the nature of the operation, it must be explosion

proof. In alignment with its environmental process objectives,

the Air National Guard emphasized the need for energy

efficiency in the facility design. Equipment reliability and

redundancy were also required to ensure the building’s

continuous operation. With F-22s waiting on the pad, a

compressed design and construction schedule was developed.

SolutionBased on a ten-year relationship with the Air National Guard

and its success on previous projects, Trane was contracted by

the project’s mechanical engineer to provide equipment and

direct digital (DDC) controls for the hangar support building.

Trane’s experience and local presence, combined with the

convenience and efficiency of using a central control system

throughout the project, led the general contractor, Nan Inc.,

to contact Trane to also discuss a solution for the specified

Programmable Logic Controller (PLC) paint booth controls.

Managing energy efficiency

The support building was designed and commissioned to

Hawaii Air National GuardTrane controls maintain complex specifications, help achieve LEED Gold CertificationOahu, Hawaii

The Hawaii Air National Guard, 154th Wing, shares the Hickam Air Force Base facilities with the Pacific Command. The base islocated on 2,850 acres of land adjacent to Honolulu International Airport. To support the painting operation and maintenance of theAir National Guard F-22 Raptor jets, a new low observable/composite repair facility was built. The facility, consisting of a 17,500 sqft hangar/paint booth and a 17,700 support building, features sophisticated mechanical systems for climate control for aircraftpainting operations.

meet US Green Building Council LEED (Leadership in Energy

and Environmental Design) requirements. LEED promotes a

whole-building approach to sustainability by recognizing

performance in site development, water savings, energy

efficiency, materials selection and indoor environmental

quality. With energy efficiency an important element of the

design, factory mounted direct digital controls (DDC) on

Trane air handlers, fan coil units and variable air volume

boxes were installed to meter and monitor energy use and

volatile organic compound (VOC) levels. The controls are

integrated into a Trane Tracer Summit® building automation

system (BAS), which facility managers use to ensure system

performance, manage energy use and perform daily tasks,

such as scheduling, alarm management and data analysis.

The Hawaii Air National Guard’s low observable/composite repair facility

includes two custom designed, mirror image paint booths.

May 2013Case study

Meeting complex specifications

Trane met with Nan Inc. to review the plans, detailed

drawings and specifications for the PLC paint booths. The

one-of-a-kind mirror image paint booth design, developed by

the engineering firm, CH2M Hill, called for a temperature of

75 degrees +/- 2 degrees and humidity levels of 50 percent

+/- 5 percent, with eighty-six feet per minute air flow across

the bay, and a -0.01” pressure between the booth and the

outside environment.

Trane consulted with Systems Integration Group, a software

programming company they had worked with on previous

projects. Familiar with Systems Integration Group’s expertise

in PLC systems, Trane hired the company as a subcontractor

to provide engineering and programming support, while

Trane designed the overall concept and system integration.

Utilizing Trane’s relationship with GE, a fully-automated,

easy-to-use GE 90-30 PLC was programmed to maintain the

custom specifications, and designed with explosion-proof end

devices. The booths are fully instrumented to control,

monitor and maintain specific air flow across the booth floor

and slightly negative pressure in the booth at all times during

the painting mode. To maintain specifications, high-quality

Trane Modular Climate Changer™ Air Handlers, designed for

reliability and longevity, were installed, as well as custom heat

wheel dehumidification units.

The booths have unoccupied, prep and purge modes that

respond automatically to input from the PLC control panel or

booth alarms. The GE PLC was integrated into the Tracer

Summit® building automation system (BAS), allowing facility

managers convenient access from a dedicated computer.

ResultsTwo custom designed paint booth hangars and a support

facility were built to maintain the Hawaii Air National Guard’s

fleet of F-22 Raptor jets. A $400,000 year-over-year savings

is anticipated, compared to other paint booth hangars, due to

an 80 percent recirculation of conditioned air and other

design features. Trane controls and Tracer Summit BAS meet

the strict standards set by project designers. The facility was

awarded a LEED Gold Certification.

“Trane understood the complex requirements,” said James

Zwiefel, Hawaii National Guard project manager. “And the

open lines of communication between Trane, our designer

and general contractor helped us more easily identify the

right solutions and made the project go smoothly.”

”We’re looking at the possibility of implementing a web-

based Tracer Summit Enterprise Server™ system to tie all

of the Air National Guard Tracer Summit sites together," said

John Yap, Hawaii National Guard building maintenance

supervisor. "One system would make it more convenient.”

The Air National Guard paint booths are fully instrumented to control,

monitor and maintain exacting temperature and humidity requirements.

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CASE-SLX339-EN May 1, 2013