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DECEMBER 2012
FEATURES
30 | How to specify an indoor lighting system
By following a few guidelines, engineers and lighting designers can specify an appropriate lighting system for a facility.
BY MIKE LARSEN, LEED AP
ON THE COVER: This building information model (BIM) rendering shows a multi-story office buildings HVAC ductwork and piping. This image was generated approximately halfway through the design process and, together with sections and walk-throughs, identified areas of the design that required additional coordination. Autodesks Revit and Navisworks programs were used to render this. Courtesy: H&A Architects and Engineers
38 | Wireless building controls

Creative use and selection of wireless devices can potentially reduce construction costs, decrease construction time, and add future flexibility to buildings.
BY MICHAEL A. CULVER, PE
COVER STORY
22 | How to select an air handling unit
Air handling units come in all shapes and sizes. Learn to balance and prioritize all of the choices related to performance, efficiency, maintainability, and space constraints.
BY ROB MCATEE, PE, AND EVAN RILEY, PE, CEM, LEED BD+C
42 | Commissioning control systems for MCFs

Controls success starts in design with clear requirements, and ends with thorough testing and complete turnover. Here are eight steps to follow.
BY JAMES MCENTEGGART, PE
DEPARTMENTS
07 | Viewpoint
Looking backwardand ahead
19 | Codes & Standards

Connecting buildings to the Smart Grid
08 | MEP Roundtable
College campus engineering
48 | New Products 63 | Advertiser Index 64 | 2 More Minutes

Meeting the challenges of globalization
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CONSULTING-SPECIFYING ENGINEER (ISSN 0892-5046, Vol. 49, No. 11, GST #123397457) is published 11x per year, monthly except in February, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONSULTING-SPECIFYING ENGINEER copyright 2012 by CFE Media, LLC. All rights reserved. CONSULTINGSPECIFYING ENGINEER is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing of ces. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630/571-4070 x2220. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONSULTING-SPECIFYING ENGINEER, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonquali ed subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to CONSULTING-SPECIFYING ENGINEER, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever. www.csemag.com Consulting-Specifying Engineer DECEMBER 2012
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Winter 2012 Pure Power
online now csemag.com

When engineering systems in colleges or universities, whats the No. 1 most difficult issue you face?
Automation and controls HVAC Codes and standards Energy efficiency, sustainability Electrical and power Fire and life safety
5 51% 26% 8% 5 5% 4% 3%
Read the Q&A about colleges and universities on page 8. For more poll results, visit www.csemag.com/poll/cse.
Read about electric vehicle charging stations and arc flash safety in the latest issue of Pure Power, a supplement of Consulting-Specifying Engineer magazine. Read more at www.csemag.com/purepower.
Read the longer versions at www.csemag.com/archives
Codes and standards: Connecting buildings to the Smart Grid MEP Roundtable: Colleges and universities Wireless building controls Would you prefer to receive this issue as a digital publication? Update your subscription, and get our digital edition, on our new more interactive platform, in your e-mail in-box: www.csemag. com/subscribe. Consulting-Specifying Engineer is now on Facebook, Google+, LinkedIn, and Twitter. Follow CSE, join the discussions, and receive news and advice from your peers. Facebook: www.facebook.com/CSEmag Google+: http://tinyurl.com/CSEgoogleplus LinkedIn: http://tinyurl.com/CSElinkedin Twitter: www.twitter.com/AmaraRozgus
Earn CEUs before the end of the year

View on-demand webcasts at www.csemag.com/webcast. Topics include: Critical Power: Whats New in Electrical Engineering: Smart Grid and Transformers HVAC for Schools: Energy Efficiency and IAQ on a Budget Fire Protection and Suppression Systems: Codes and Technology Update Critical Power: Emissions Regulations and Technologies Whats New in Data Centers: Architecture-Driven Cooling and Electrical Designs Electrical Distribution: Innovative Approaches That Save Money Strategies for Implementing Energy Efficient Data Centers Critical Power: GensetsDesigning Reliable and Flexible Emergency and Standby Power Systems
Electric, power business perspective video

This one-on-one video with Schneider Electrics Jeff Drees looks at an overview of the Schneider Electric business and market trends, and offers advice for engineers. Scan the QR code to watch video
40 Under 40
Consulting-Specifying Engineer magazine is dedicated to encouraging and recognizing the most talented young individuals in the engineering community supporting the building industry. Support the young professionals and nominate them to the 2013 40 Under 40 program. Nominations are due Feb. 8, 2013. Nominate someone today: www.csemag.com/40under40.
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Editors Viewpoint
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 630-571-4070 Fax 630-214-4504
CONTENT SPECIALISTS/EDITORIAL CONTENT SPECIALISTS/EDITORIAL AMARA ROZGUS, Editor in Chief/Content Manager

630-571-4070, x2211, ARozgus@CFEMedia.com AMARA ROZGUS, Editor in Chief/Content Manager 630-571-4070, x2211, ARozgus@CFEMedia.com AMANDA MCLEMAN, Project Manager 630-571-4070 x2209, AMcLeman@CFEMedia.com AMANDA MCLEMAN, Project Manager 630-571-4070TAYLOR, Project Manager BEN x2209, AMcLeman@CFEMedia.com 630-571-4070, x2219,Content Manager BOB VAVRA, BTaylor@CFEMedia.com 630-571-4070, x2212, BVavra@CFEMedia.com BOB VAVRA, Content Manager 630-571-4070, x2212, BVavra@CFEMedia.com MARK HOSKE, Content Manager 630-571-4070, x2214, MHoske@CFEMedia.com MARK HOSKE, Content Manager
Amara Rozgus Editor in Chief
630-571-4070, x2214, MHoske@CFEMedia.com PETER WELANDER, Content Manager 630-571-4070, x2213, PWelander@CFEMedia.com PETER WELANDER, Content Manager
630-571-4070, x2213, PWelander@CFEMedia.com MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEmedia.com MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEmedia.com CHRIS VAVRA, Content Specialist 630-571-4070, x2219, Content Specialist CHRIS VAVRA, CVavra@CFEMedia.com
Looking backwardand ahead
CVavra@CFEMedia.com BRITTANY MERCHUT, Content Specialist 630-571-4070,MERCHUT, Content Specialist BRITTANY x2220, BMerchut@CFEMedia.com 630-571-4070, x2220, BMerchut@CFEMedia.com
EDITORIAL ADVISORY BOARD EDITORIAL ADVISORY BOARD

ANIL AHUJA, PE, LEED AP, RCDD, ANIL AHUJA, PE, LEED AP, RCDD,
President, CCJM Engineers, Chicago President, CCJM Engineers, Chicago
PATRICK BANSE, PE, LEED AP, PATRICK BANSE, PE, LEED AP,
Senior Mechanical Engineer, Senior Mechanical Engineer, Smith Seckman Reid Inc., Houston Smith Seckman Reid Inc., Houston
Principal, Metro CD Engineering LLC, Dublin, Ohio Principal, Metro CD Engineering LLC, Dublin, Ohio Fire Protection Engineer, Clark County Building Division, Las Vegas Fire Protection Engineer, Clark County Building Division, Las Vegas
MICHAEL CHOW, PE, LEED AP BD+C, MICHAEL CHOW, PE, LEED AP BD+C, DOUGLAS EVANS, PE, FSFPE, DOUGLAS EVANS, PE, FSFPE, RAYMOND GRILL, PE, FSFPE, RAYMOND GRILL, PE, FSFPE,
Principal, Arup, Washington, D.C. Principal, Arup, Washington, D.C.
Associate Electrical Services Engineer, Associate Electrical Services Engineer, KlingStubbins, Philadelphia KlingStubbins, Philadelphia
PAUL BEARN, PE, PAUL BEARN, PE,
President, Environmental Systems Design Inc., Chicago President, Environmental Systems Design Inc., Chicago President, Conservation Lighting Intl. and Building Conservation President, Conservation Lighting Intl. and Building Conservation Intl., Philadelphia Intl., Philadelphia Managing Principal, EYP Mission Critical Managing Principal, EYP Mission Critical Facilities Inc., Chicago Facilities Inc., Chicago Electrical Engineer CH2M Hill, Portland, Ore. Electrical Engineer CH2M Hill, Portland, Ore.
RAJ P. GUPTA, PE, LEED AP, RAJ P. GUPTA, PE, LEED AP, GERSIL KAY, GERSIL KAY,
WILLIAM KOSIK, PE, LEED AP, WILLIAM KOSIK, PE, LEED AP,
TIMOTHY E. KUHLMAN, PE, RCDD, TIMOTHY E. KUHLMAN, PE, RCDD,
KEITH LANE, PE, RCDD, LC, LEED AP, KEITH LANE, PE, RCDD, LC, LEED AP,
President, Lane Coburn & Assocs., Seattle President, Lane Coburn & Assocs., Seattle
President, Lovorn Engineering Assocs., Pittsburgh President, Lovorn Engineering Assocs., Pittsburgh Senior Mechanical Engineer, Stanley Senior Mechanical Engineer, Stanley Consultants Inc., Chicago Consultants Inc., Chicago Associate Principal, Arup, Los Angeles Associate Principal, Arup, Los Angeles Senior Engineer, Camp Dresser & McKee Inc., Senior Engineer, Camp Dresser & McKee Inc., Cambridge, Mass. Cambridge, Mass. President, CEO, The RJA Group Inc., Framingham, Mass. President, CEO, The RJA Group Inc., Framingham, Mass. Electrical Platform Leader and Quality Assurance Manager, Electrical Platform Leader and Quality Assurance Manager, M+W Group., Chicago M+W Group., Chicago Senior Engineer, Facility Dynamics Engineering Inc., Portland, Ore. Senior Engineer, Facility Dynamics Engineering Inc., Portland, Ore. Principal, Senior Electrical Engineer, TLC Engineering Principal, Senior Electrical Engineer, TLC Engineering for Architecture, Jacksonville, Fla. for Architecture, Jacksonville, Fla.
KENNETH L. LOVORN, PE, KENNETH L. LOVORN, PE, ALI MAHMOOD, PE, ALI MAHMOOD, PE,
ERIN MCCONAHEY, PE, ERIN MCCONAHEY, PE,
SYED PEERAN, PE, Ph.D., SYED PEERAN, PE, Ph.D.,
MARTIN H. REISS, PE, FSFPE, MARTIN H. REISS, PE, FSFPE,
BRIAN A. RENER, PE, LEED AP, BRIAN A. RENER, PE, LEED AP, DAVID SELLERS, PE, DAVID SELLERS, PE,
GERALD VERSLUYS, PE, LEED AP, GERALD VERSLUYS, PE, LEED AP, MIKE WALTERS, PE, LEED AP, MIKE WALTERS, PE, LEED AP,
Principal, Confluenc, Madison, Wis. Principal, Confluenc, Madison, Wis. Principal, GRAEF, Milwaukee Principal, GRAEF, Milwaukee
ll sentimentality aside, December is the perfect time to review where weve been so we know where were going. Heres a look at 2012with a peek at 2013. January: In 2012, I encouraged you to become more energy efficient, and while this is sometimes easier said than done, January is the perfect time to create new habits and set new goals. March: This months editorial focused on water conservation. Many building systems use water at some point, and we all rely on our local water source in our personal lives. Make March the month you vow to conserve more water. April: CSEs annual Product of the Year awardswhich opens Jan. 2, 2013highlight products that help us do our jobs better. Stay tuned to www. csemag.com/POY. May: In May each year, we honor young individuals who embody all the positive aspects of our industry. Nominate a young professional to the 2013 40 Under 40 awards program: www. csemag.com/40under40. June: June is your chance to share success stories. Share your case studies by sending them to arozgus@ cfemedia.com. July: In July, my editorial discussed high-performance buildings, and the technologies and systems associated
with them. This is obviously a recurring trend, not only in the pages of this magazine, but also in the buildings industry overall. August: We honor the MEP Giants in August each year. We will consider your firm if your gross annual revenue is at least $1 million. For more information, visit www.csemag.com/giants. September: Each quarter, the Pure Power supplement focuses on all things power: generators, selective coordination, arc flash, etc. Electrical systems continue to be crucial to a buildings success, and renewable energy and electrical efficiency are creeping into the pages of this supplement. October: Commissioning has become not only more prevalent but essential to the success of a new or existing building. Our annual coverage discusses this topic from all angles. November: As discussed last month, we are conducting even more research to better understand your challenges and needs. If you receive a survey via e-mail, I encourage you to participate. December: With the year coming to an end, we all look forward to a new start. Let this month be the month you decide to take on that new class, volunteer for a new project, or write that technical article youve always dreamed of.
PETER D. ZAK, PE, PETER D. ZAK, PE,
Send your questions and comments to:

ARozgus@CFEMedia.com
www.csemag.com
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MEP Roundtable
PARTICIPANTS
College campus engineering

Colleges and universities bear the important responsibility of molding the minds of future generations. To tackle the formidable task, such institutions require the expertise of engineers to ensure the complex buildings on campuses (laboratories, classrooms, computer centers) meet their needs.
Michael Broge Principal Affiliated Engineers Inc. Madison, Wis.
CSE: What engineering challenges do college buildings pose that are different from other structures? Michael Broge: Colleges and universities capital and operational budgets are severely limited in todays economic climate. Buildings are now almost always designed with the intention of being 50- to 100-year buildings and the energy efficiency of mechanical, electrical, plumbing (MEP), and fire protection systems is a priority. In many types of buildings, those systems are designed with significant flexibility to accommodate multiple reconfigurations over the course of those extended building lifespans. Preferences for low-maintenance system types reflect the reality of reduced maintenance budgets. Joseph Lembo: Many of the higher education facilities that we deal with have aging central plants and infrastructure with minimal spare capacity. Designing for a major renovation or new building on such a campus requires extensive analysis on the existing central plant and how it is currently operating. Oftentimes a campus can go through a period in which several new and renovated facilities are constructed with no substantial plant upgrades. However, a point will come in which a single project will trigger a major campus infrastructure upgrade. We endorse the notion that higher education facilities allocate capital for infrastructure as a part of any major project. In doing so, this would avoid the burden of a single project absorbing the cost of upgrades. Rick Maniktala: Engineers working on col-
Joseph Lembo, PE Partner Kohler Ronan Consulting Engineers Danbury, Conn.
lege campuses must understand the unique challenges their structures pose, the most significant of which is to understand the ways in which the structures are interconnected to one another across the campus, often sharing and/or hosting infrastructure services such as: chilled water, heating hot water or steam, fiber telecom services, electrical power transformers, water services, etc. The interconnection extends beyond infrastructure as they often serve as passageways with interior or below-grade corridors providing students with shelter as they travel across campus. There often isnt good as-built documentation for the interconnections, so extensive field investigation is required.
CSE: How have the needs and characteristics of colleges changed in recent years? Lembo: The American College & University Presidents Climate Commitment has driven many of the higher education facilities to place sustainability in the forefront of most new projects. We have found that it is critical to coordinate with the architect early on in the project to develop an envelope to help minimize the energy consumption of a building, prior to commencing schematic design. In-house energy simulation modeling has allowed our firm to analyze energy consumption early on and present this information to allow the owner and architect to make key decisions early on. Maniktala: In recent years, colleges and
Rick Maniktala, PE, LEED AP, CxA, DBIA, HFDP Principal/Vice President M.E. Group Overland Park, Kansas
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The team at Kohler Ronan Consulting Engineers worked with architect Robert Stern on Marist Colleges Hancock Center for Emerging Technology. The 54,000-sq-ft building features computer laboratories, work/study spaces, backup disaster recovery center for IBM, and use of natural light throughout. Courtesy: Kohler Ronan Consulting Engineers
universities have become increasingly competitive with building projects. They strive to maintain an advantage and attract students by improving the structures that support student life and their aspirations. New, innovative advanced degree programs are in demand and have been created while campuses race to offer these to students. Masters-level business programs with an emphasis on innovation and technology are in demand and have necessitated the expansion of degree programs and the construction of new buildings to support this growth. Broge: Complexity has grown relative to systems, regulations, and project delivery. As the sustainable design movement has matured, many institutions have moved from self-certification of U.S. Green Building Council LEED-designed project to formal LEED application and certification. State governments have developed or are developingenergy efficiency standards for public buildings that significantly exceed state energy codes. The emphasis on sustainability and
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energy efficiency often further complicates already complex building systems and controls, and many institutions are concerned about the related costs of maintaining these sophisticated technologies. College and university facilities management staff are much more involved in building design now than they were 10 years ago, reflecting a need to design to the institutional maintenance culture.
CSE: Many learning institution administrators are choosing to expand and remodel existing facilities rather than construct new buildings. What unique challenges do retrofitted buildings present that you dont encounter on new structures? Maniktala: Existing buildings on college campuses often have infrastructure services that are inefficient when compared to todays standards. For example, an existing school of pharmacy building was converted to the school of
architecture and urban planning. While the initial budget did not include the replacement of the existing constant volume dual duct air handlers with air cooled direct-expansion (DX) coils, the potential energy savings for doing so could not be ignored. Unsure whether the infrastructure upgrade could be afforded, the university elected to include an alternate design with total replacement of all the dual-duct air handling units (AHUs) to new single-duct variable air volume (VAV) units with hot water reheat terminals. The bids were favorable and the project moved forward with the modernization of the infrastructure AHUs, hydronic heating water system, campus chilled water tiein, electrical service, etc. This example is not unique; many existing buildings on campuses across the country would benefit immediately from similar infrastructure upgrade/modernization projects to reduce energy consumption and improve thermal comfort and indoor air quality. Broge: Older buildings structural elementsthat is, columns, beams, and
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MEP Roundtable
floor-to-floor heightsare generally fixed and extremely costly to modify, often presenting limitations to building programming and use. For example, the floor-to-floor heights of buildings predating current ventilation standards could either dictate additional vertical air distribution or simply spell obsolescence. Existing facades generally are more likely to invest in certain renewable energy technologies than many client types. Systems using geothermal, solar hot water heating, and photovoltaic (PV) power generation technologies have become increasingly common in our project work. The effectivenessand, thus, advisabilityof these applied renewable into effect, and may impact installed cost. Lembo: We have found institutional clients more receptive to innovative design strategies since many judge project merit based on intrinsic educational value and environmental impact rather than pure economics. Past successes for these clients include ground-source heat pumps (GSHPs) supplemented by solar evacuated tubes, passive outside air (OA) preconditioning via earth-ducts, and extensive use of PV. However, many colleges still find these types of systems impractical after weighing associated energy savings and environmental benefits against increased lifecycle costs. For a design to make it through the value engineering process intact, we have to leverage project-specific synergies and demonstrate tangible financial justification. In general, the majority of renewable energy installations benefit from grid parallel net metering. However, many utility providers preclude college campuses with distributed energy systems from participating in net metering contracts. Without the ability to use the grid as a battery, designing practical and financially justifiable on-site generation requires synchronizing energy production with energy demands. We have had success on several campus projects incorporating thermal energy storage (TES) to decrease losses from unused production and systematically control the release of energy to match HVAC loadsall while reducing installed chiller size. Recently our firm conducted an energy master plan for a college campus with a combined cycle power plant. General consensus prior to the study was that the campus needed additional capacity to meet energy demands. After extensive energy modeling and loads analysis, it was determined that TES could buffer demand shifts enough to capture an additional 30% of energy already being produced by the campus but not being used.
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For a design to make it through the value engineering process intact, we have to leverage project-specific synergies and demonstrate tangible financial justification. Joseph Lembo
require upgrades with increased insulation, vapor barriers, and new window configurations, all of which may very well prove to be prohibitively costly to perform. Finally, renovations raise vital scheduling questions. A lack of significant available swing space to house large user groups during renovations will require phased renovations, relocating a sequence of smaller user groups. And phased renovation requires management of disruptions and inconveniences to adjacent users, including construction noise, dust, and periodic unplanned infrastructure outages. Lembo: Existing buildings have aging infrastructure and envelopes that were built to earlier standards which were significantly less energyefficient. Developing a plan of passive envelope and active mechanical approaches to not only improve energy efficiency but also incorporate sustainable design elements is important. This is where the collaborative design effort is required from all design team members. technologies is largely dependent upon the geographic and climatic location of the project and the purpose for incorporation of the technology itself. For example, we designed a geothermal system as part of a building renovation at a larger public Midwestern university for the purpose of providing required environmental cooling after the central campus chilled water system was shut down for the winter. This application was successful in not only providing winter environmental cooling, but also providing nearly all of the buildings yearround heating and cooling energy. A less successful geothermal application was designed for a research building at another large public Midwestern university that requested the system for demonstration purposes. The complexity of this system has created challenges to balance the systems thermal characteristics and to operate effectively. The use of PV technology in mass scale has been hindered in large part due to the high cost per installed wattabout $10/W a few years ago, though we have designed several demonstration projects corresponding to that number. Current installed PV costs are nearer $5/W due to improvements to the technology and greater familiarity with its installation. New building codes pertaining to PV are just coming
CSE: What renewable energy systems have you specified on a college campus, and what were the results? Broge: Colleges and universities
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MEP Roundtable
Maniktala: The Student Learning and Engagement Building at the Community College of Denver (CCD) will consolidate most of CCDs administrative and teaching spaces into a single location. The 86,000-sq-ft project includes many high-performance features to enhance occupant performance, reduce energy consumption, and improve the students connection with the outdoors. These include natural ventilation strategies,
always the question. One successful method is to implement window sensors interlocked with the air conditioning unit. It is common to walk through an occupied dorm that is conditioned with windows wide open and the air conditioning unit operating. Adding window sensors would de-energize the air conditioning unit when windows are left open. Broge: Most building codes change
the large amount of servers planned for the data center.

CSE: How do such codes/standards vary from region to region? Lembo: We are noticing that many states have their own specific mandates. We recently completed a performing arts center design at New Mexico State University. The project needed to meet a governors mandate in which energy consumption in a newly constructed building shall be 50% better when compared to a building of similar use and occupancy. Similarly, we see such mandates in Connecticut, in which any state-funded projects must perform 21% better than ASHRAE Standard 90.1-2007 for energy costs. Broge: We have seen state and regional codes across the country becoming somewhat more uniform as the International Building Code series has gained acceptance. State and local code authorities are gradually removing their state-isms from their own unique code requirementsand are becoming more accepting of the international code requirements as they are written. There continue to be exceptions, but standardization of codes and standards will obviously help the design community with both design improvement and code compliance.
State and local code authorities are gradually removing their state-isms from their own unique code requirementsand are becoming more accepting of international code requirements as they are written. Michael Broge
radiant heating and cooling, active chilled beams, daylight harvesting, and advanced addressable lighting controls. A highly efficient chilled beam system will provide heating, cooling, and ventilation to the building. Combined with a simple boiler chiller plant, this design will reduce maintenance requirements, maximize energy efficiency, and offer flexibility for future renovations. By joining these advanced MEP design strategies with a building massing and envelope design that has been optimized through energy modeling, we anticipate that this project will use only 50% of the energy required for the baseline building. The project is targeting LEED Gold. gradually over a period of time, allowing both the designers and owners to become versed with most code changes and their design impacts. Sustainability codes and standards have been more accelerated, significantly impacting the design of institutional systems. State and institutional enactment of significantly better than code energy standards, particularly in certain high-energy-consuming building types, has created challenges. We are currently involved in the design of a larger institutional physical sciences research building whose program includes a large high-density data center. The building model predicted the data center would account for more than 50% of the entire buildings energy consumption. The state requires the building, including its processes, to be 30% more energy efficient than the energy code allows. With a fixed budget, and with limitations on the use of renewable energy sources, it became impossible to meet the requirement without significant diversion of the projects program fundinga scenario that could well result in a reduced project program space. Fortunately, the state agency regulating state building projects was able to grant an exception to the energy consumed by
CSE: How have changing HVAC, fire protection, and/or electrical codes and standards affected your work in colleges? Lembo: It is rare to find a dormi-
CSE: What trends, systems, or products have affected changes in fire detection/suppression systems in colleges? Lembo: Due to the various tragic dormitory type fires (and close calls) across the country, many institutions have taken a progressive approach in protecting their assets (students and faculty) by installing fire sprinkler systems within new construction or, more importantly, retrofitting existing buildings. Many other jurisdictions in which
tory building constructed 30 years ago with air conditioning for each residential unit. Today, air conditioning each individual unit is a standard adopted by many higher educational facilities. How to reduce the energy consumption with the addition of air conditioning is
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universities reside have instituted local ordinances, making fire sprinklers a requirement. Over the years there has been an increased sensitivity among campuses regarding fire safety, security, early notification, etc., and networking these components together is the ultimate goal; fire sprinklers are only one major facet. Students as well as parents have increased their expected levels of protection. Installing fire sprinklers ultimately and indirectly creates a higher level learning environment.
CSE: What unique requirements do HVAC systems in colleges have? Broge: Our firm primarily designs technically complex science and technology buildings for our college and university clients. By their nature, these buildings consume large quantities of
energy, generally with HVAC systems leading the consumption. Our institutional clients place great emphasis on designing safe yet sustainable HVAC systems. Another priority is to design systems that require less maintenance, generally requiring systems with fewer components and less complex equipment. We will often use larger fans and pumps so we can reduce the number of them. Lembo: Properly sizing of HVAC systems to address the diversity due to occupant fluctuations. The concern is not to oversize the mechanical systems which could attribute to higher energy usage.
CSE: Describe the use of fans and ventilation equipment to enhance indoor air quality (IAQ) in a recent college project.
Lembo: In designing two recent dormitories for Fairfield University, first ventilation air was increased by 30% greater than ASHRAE Standard 60.1; finally, the design employed an energy recovery wheel that would pretreat the outside air with the exhaust air removed from the building. Broge: For the research buildings our firm normally designs, IAQ is addressed through a variety of technologies and strategies. Research buildings by nature have considerable quantities of oncethrough air (outside air that is used for a single ventilation pass in the building and then exhausted). This flushes contaminants and odors from laboratories where a return air system would simply spread contaminants to other spaces. We use air movement and space pressurization strategies to contain and remove space
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MEP Roundtable
contaminants by cascading ventilation air from cleaner spaces to dirtier spaces, such as from a corridor to a laboratory. Use of higher ventilation air filtration efficienciesperhaps 90% efficient filtersis also commonly used today.
CSE: Describe a recent boiler or chiller plant college campus project. Broge: Our firm is currently in final design of a larger project that will
Research buildings by nature have considerable quantities of once-through air (outside air that is used for a single ventilation pass in the building and then exhausted). Michael Broge
When we design larger classrooms and lecture spaces, we try to use such distribution strategies as vertical displacement ventilation to more directly carry contaminants away from occupants. We are considering all of the above strategies in an engineering sciences building currently under design. expand an existing central campus chilled water plant. The addition will function as a totally separate plant. The project will add 10,000 tons of new capacity (two 5,000-ton electric drive chillers) in a building sized to allow for an additional 20,000 tons to be added in the future. Four 5,000-ton cooling tower cells will be installed with the initial
work, with roof framing and support for two additional 5,000-ton towers cells in the future. The initial installation of the four tower cells will lower condenser water temperatures and result in a net energy savings. Another design feature of the new plant is the use of electric drive variable flow primary pumping into a central campus distribution system that is currently connected with three existing plants set up to pump in a primary/secondary arrangement. New 54-in. chilled water supply and return mains will be bored under an existing greenhouse complex to connect to existing campus infrastructure. Controls will comply with the North American Electric Reliability Corp. (NERC) standards due to the existing power generation complex.
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12/4/2012 11:03:49 AM
Career Smart
BY MARK GOODALE, Morrissey Goodale LLC, Newton, Mass.
Use personality typing to increase profits

Personality typing can be a valuable tool in helping your firm transform the way it does work, which can be a significant advantage in this economy.
iven that labor is typically a mechanical, electrical, plumbing (MEP), and fire protection engineering firms largest single expense, it makes sense to do everything you can to maximize your return on that investment. Personality profiling is one tool you can use to help leverage individual strengths, build trust, and increase collaboration throughout your firm. This kind of cultural transformation increases productivity, improves project management and client service, and ultimately leads to the creation of high-performance teams that generate superior deliverables, greater revenue, and increased profitability. A few examples of the many typing tools in use today include the DISC Assessment, Keirsey Temperament Sorter, Myers-Briggs Type Indicator, Predictive Index, and Socionics. Each of these typing tools can be used in a variety of ways to increase the return on the investment you make in your people. Heres how: Hiring: The candidate assessment and selection process in MEP firms can be inconsistent, subjective, and inefficient. And hiring the wrong person for a position, or someone who doesnt fit well into your firms culture, is a costly mistake. Personality typing, as one of the evaluation tools, can help you to select the best candidate for a specific role and for long-term fit within your firm. Individual integration: You may
have used personality assessments to hire your new principal, but you may want to consider it for getting him quickly integrated with his team. One of the best ways to onboard a new team leader is to provide valuable insight on his team members so he can know how to work with them more effectively. Personality typing can provide that information at a glance and significantly reduce the learning curve, leading to a higher level of production. Communication/conflict resolution: In consulting firms, how well internal teams work together directly impacts the bottom line. Part of the problem affecting team efficiency may be a basic lack of understanding of team members differing perspectives, priorities, and motivatorsand a lot of time and energy gets wasted on misattributing behaviors and attitudes. Typing tools often provide a mechanism to gain that understanding and help team members break down barriers to healthy debate and collaboration. Team building: For teams that exhibit dysfunctions like a lack of trust, a fear of conflict, or a lack of accountability, personality typing can provide the basic understanding to begin improving the communication process and helping team members become more reliable, responsible, and engaged. Once people are aware of how their teammates prefer to communicate, process information, and be rewarded,
they can learn how to work together more effectively. Merger/acquisition assessment: In the same way that you might evaluate the character traits, preferences, and motivations of an individual in comparison to the requirements of a particular position, you can compare the measured traits of a firm being acquired against those of the acquirer (buyer). Statistical comparison of either all employees or a comparable subset in both firms (project managers, principals, etc.) could show how compatible or incompatible the personalities/cultures of each firm are and pinpoint the differences. Merger and acquisition integration: MEP firms can also conduct a global personality assessment after a merger or acquisition to understand where the overlap and differences are in the overall personalities and cultures of the two firms and to speed up integration. Once the people in each of the firms begin to understand each other, they can accommodate for differences in communication styles, preferences, and motivations, and more rapidly learn how to work together as a cohesive team. Mark Goodale co-founded Morrissey Goodale. He specializes in organizational development, strategic planning, mergers and acquisitions, marketing, and executive search, and is a trusted advisor and coach to dozens of industry executives.
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12/4/2012 11:07:15 AM
Codes & Standards

Connecting buildings to the Smart Grid
Engineers should know the NIST and ASHRAE standards for the Smart Grid, and be aware of the availability of Smart Grid-ready products for commercial buildings.
By Mark Fisher, Pe, LeeD aP, Alfa Tech, San Jose, Calif.
lectrical power is delivered from power generation plants to our homes and businesses through a nationwide network of electrical distribution equipment including cables, transformers, protective devices, switches, and other equipment. This network is known as the grid. Traditionally, electrical utilities have managed this grid manually, which means workers travel to each user site to read meters. When outages occur, central office staff wait for user phone calls to learn where power is out and then send linemen to investigate. During heavy usage periods, staff may add generating capacity, purchase additional power on the spot market, or, most drastically, turn off blocks of users (rotating blackouts). In an effort to bring the grid into the 21st century, technology is being applied to make a Smart Grid capable of automating much of this work through sophisticated communications and automated responses. As noted by the U.S. Dept. of Energy (DOE), Much in the way that a smart phone these days means a phone with a computer in it, Smart Grid means computerizing the electric utility grid. It includes two-way digital communication technology to devices associated with the grid. The Smart Grid is not necessarily designed to increase profitability for utilities, but it will have many far-reaching effects. It will increase reliability by automatically bypassing outages to maintain power downstream. It will manage electrical usage and production, enabling use of intermittent but valuable renewable sources and, sometimes, directing power where it is most needed. It will also increase efficiency and cost savings by allowing users to access information and allow them to turn items on or
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off remotelyeven if they are not home. Additionally, new products may enable automatic demand response, allowing utilities to automatically control electrical usage during periods of high demand by remotely controlling lighting, air conditioning, and other equipment. As with any new technology in the power sector, it must be coordinated with hundreds of utilities and millions of users across the country. Numerous public and private entities have been involved in the development of the Smart Grid, including the DOE, National Institute of Standards and Technology, National Science and Technology Council, Federal Smart Grid Task Force, and numerous stakeholders from industry and academia. This article will present an update on current standards as well as touch on new products that have been specifically designed for use on the Smart Grid that impact building designers.
Developing standards
The National Institute of Standards and Technology (NIST) is a government agency founded in 1901 whose mission is to advance measurement science, standards, and technology. A physical laboratory, NIST has been tasked to lead the effort to develop standards for the Smart Grid. Since 2007, the agency has been working on the development of a variety of standards including communication technologies (Internet protocols), smart car plug standards, pricing standards, meter output, and a home appliance communication protocol. In fact, NIST is currently working on 20 different Priority Action Plans (PAPs). This is just the tip of the iceberg. It is estimated that hundreds of standards will
In an effort to bring the grid into the 21st century, technology is being applied to make a Smart Grid capable of automating much of this work through sophisticated communications and automated responses.
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Codes & Standards

be required to build an effective and efficient Smart Grid. Many of the standards involve communicating information and developing demand response capabilities. Typical standards include Wireless and Power Line Communication for the Smart Grid, Electric Storage Interconnection Guidelines, and Wind Plant Communications. mented on several NIST proposals. In addition, the Government Accountability Office has noted that While EISA gives FERC authority to adopt smart grid standards, it does not provide FERC with specific enforcement authority. So where should specifiers go for guidance, and how do we avoid incompatibility issues associated with a lack of dations. While this organization has not formally endorsed any protocols, it has made evaluations and recommendations, indicating that Zigbee, Wi-Fi, and Home Plug Green PHY are the top three most suitable communication protocols based on the analysis. AHAM has also recommended various features that appliances should have for interaction of the Smart Grid with consumers. The Institute for Electrical and Electronics Engineers (IEEE) has developed more than 20 Smart Grid related standards covering everything from Control of Small Hydroelectric Plants to Collecting and Managing Transmission Line Inspection and Maintenance Data. As the Smart Grid matures, so will the products and services that support it. It is incumbent on design engineers to stay aware of the multitude of options available in order to design intelligent systems and advise their clients of the various possibilities. Engineers also will need to keep current on future standards as they are developed and approved to make sure designs meet the latest system requirements and all devices can effectively communicate, allowing the Smart Grid to maximize its potential.
Smart Grid-ready products
As the Smart Grid matures, so will the products and services that support it. It is incumbent on design engineers to stay aware of the multitude of options available in order to design intelligent systems and advise their clients of the various possibilities.
A NIST standard that directly affects todays building designers is the electric vehicle plug standards entitled Common Object Models for Electric Transportation. This standard includes plug and charging configurations, including allowing charging at different voltages and charge rates in a safe manner. In addition, the standard addresses the ability to control the impact of charging on the grid through price or direct control. Allowing electric vehicles to sell power back to the grid during periods of high demand is addressed. Finally, the standard addresses providing a fair settlement to everyone when the vehicle is charged away from home. Most manufacturers of electrical distribution equipment offer a compliant charging station.
Approved standards
Specifiers of electrical equipment need to make sure that the products they are promoting meet required standards. As Smart Grid technology is in its infancy, there are not a lot of standards available to guide specifiers. The Energy Independence and Security Act of 2007 gave the responsibility for adopting NIST recommended standards to the Federal Energy Regulatory Commission (FERC). To date, FERC has not adopted any of the recommended standards, although it has reviewed and com20
standards? Independent agencies such as ASHRAE, National Electrical Manufacturers Assn. (NEMA), and others have also been developing and promoting Smart Grid standards. For example, ASHRAE recently teamed up with NEMA to develop ASHRAE/NEMA Standard 201P, Facility Smart Grid Information Model. As noted on ASHRAEs website, the proposed standard 201P would define an object oriented information model to enable appliances and control systems in homes, buildings, and industrial facilities to manage electrical loads and generation sources in response to communication with the smart electrical grid and to communicate information about those electrical loads to utility and other electrical service providers. The model includes information on lighting, heating, air conditioning, and other electrical loads. It will simplify communication for energy providers by providing a common information path for all building types. On the facility side, it allows products designed for residential use to be used in commercial buildings and vice versa. The model is coordinated with standards developed by NIST. The Assn. of Home Appliance Manufacturers (AHAM) has also started to review standards and make recommen-
There are a number of available Smart Grid-ready products and services that affect building and facility designers. These include direct load control devices, Web portals for automated metering via the Internet, in-home displays, and programmable communicating thermostats. Mark Fisher is head of the electrical department at Alfa Tech Consulting Enterprises. His expertise is in sustainable design, and he has written white papers on plug load reduction and commercial kitchen energy reduction. He is a member of the California Division of the State Architects Green Committee and the Illuminating Engineering Societys Library Lighting Committee.
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12/4/2012 11:08:48 AM
How to select an air handling unit

A
basic definition of an air handling unit (AHU) might be a box with a fan, coils, and filters. From there it gets considerably more complicated. Proper selection of an air handler requires answering myriad questions ranging from what capabilities are required? to will it fit? Only after establishing these basic project constraints can the art of evaluating and selecting an AHU begin. Before starting this process, its important to realize that there will not be a perfect selection for any AHU as many competing criteria, not the least
Air handling units come in all shapes and sizes. Learn to balance and prioritize all of the choices related to performance, efficiency, maintainability, and space constraints.
BY ROB MCATEE, PE, and EVAN RILEY, PE, CEM, LEED BD+C, H&A Architects and Engineers, Glen Allen, Va.
Learning objectives
Know the different types of AHUs, and their basic anatomy Understand the codes and standards that govern AHU specification Learn about how energy can be saved in HVAC systems that use AHUs.
being cost, will force compromises. It is the engineers job to balance and prioritize all of the decisions related to performance, efficiency, maintainability, and space constraints to select a unit that has the lowest lifecycle cost for a given application. This article provides general information and guidance on the selection of various AHU components, starting with a brief description of the major categories of AHUs. While much of the discussion in the remainder of the article relates primarily to large AHUs, the general considerations can be applied to any size.
Figure 1: This side-view cutaway drawing of a draw-through AHU shows the plenum return fan, exhaust/mixing boxes, filters, cooling coil, humidifier, heating coil, and plenum supply fan. Note that no preheat coil is present as this unit receives pretreated outside air from a dedicated outside AHU. Courtesy: H&A Architects and Engineers
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Types of AHUs
Fan coils/blower coils are the smallest and simplest category of AHU and, as the names imply, they typically consist of little more than a fan and a heat transfer coil(s). To keep the coils from getting dirty too quickly, a simple filter is also included. They generally have simple controls and serve a single temperature zone. While they have their applications, they are typically less efficient than larger AHUs and have difficulty providing tight temperature and humidity control. Packaged AHUs are very common in smaller buildings and commercial applications, particularly as rooftop units. Packaged units generally contain fans, coils, filters, and dampers in a single casing. Often the casing includes its own air conditioning compressors and means for heating such as gas burners, electric heating coils, or heat pump coils. They often serve single temperature zones, but large variable air volume (VAV) AHUs serving multiple terminal boxes (zones) are available. Because of their compactness and lower initial costs, packaged units have a reputation for being inefficient and maintenance intensive, but performance and reliability are improving. They are available in sizes from a few thousand cfm to more than 30,000 cfm, but their standardization can be limiting in some applications. Modular AHUs allow users to select individual components housed in modules having consistent construction and cross sections. The user can select the type of casings, fans, filters, coils, and accessories from a variety of different options. Modules are assembled at the factory or can be shipped individually and assembled onsite. Modular units generally allow great flexibility and can meet most air processing requirements. Custom AHUs are available in nearly any configuration that a user might require. They generally have the highest quality construction and are most commonly used in institutional or industrial applications where high flow rates, very close control, and harsh conditions exist. They may also be applied in irregular spaces that would not conform to a
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Figure 2: This building information model (BIM) rendering shows a multi-story office buildings HVAC ductwork and piping. This image was generated approximately halfway through the design process and identified areas of the design that required additional coordination. Autodesks Revit and Navisworks programs were used to render this. Courtesy: H&A Architects and Engineers
modular line. Custom units can be configured to include virtually any combination of air processing components. They also can include walkways and service areas within them and can even accommodate space for skid-mounted equipment like pumps or heat exchangers. They are the most costly of all of the types of units discussed, but can be expected to have the longest lifespan.
Anatomy of an AHU
Casing and construction: A quality AHU can last more than 30 years with proper maintenance. Double-walled construction is now standard for all but the smallest units, but the application of the insulation between the walls also is important. Injected foam insulation with no through-metal connections (no thermal bridging) is available from a variety of manufacturers and generally has better thermal and acoustical performance than fiberglass insulation. If the unit is to be installed outdoors, extra insulation is
recommended and corrosion-resistance should be a top priority. Mixing box: Most AHUs supply some percentage of outside air for ventilation. The mixing box is the place where outside air is combined with return air from the building. Control dampers are used to proportion the incoming airstreams and relief air. Filters: Air filters remove contaminants from the airstream and significantly improve indoor air quality (IAQ). Rating systems for air filters, such as ASHRAE Standard 52.2-2007, Method of Testing General Ventilation Air-Cleaning Devices for Removal Efficiency by Particle Size, define the mean efficiency reporting value (MERV) providing a comprehensive and consistent indication of a filters capture performance with a range of particle sizes. Newer rating systems, such as the European Committee for Standardization EN779:2012, rate air filters based not only their ability to capture particles, but also on their predicted annual energy use. It
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It is the engineers job to balance and prioritize all of the decisions to select a unit for a given application.
airstream without having to subcool the supply air as is necessary for draw-through units. Although much less common than draw-through, blow-through units do have applications, particularly in healthcare. They also are seeing increased application in low-temperature air systems.
Figure 3: On this AHU controls and starters have been installed prior to unit shipping. This often reduces overall project cost and start-up time. Courtesy: Buffalo Air Handling
Fan selection
is expected that a similar approach will adopted in the United States in the coming years. The lifecycle cost of filters should be carefully considered during the design and subsequent purchasing of the filters. Overall, the first cost of filters can be as little as 4% of the lifecycle cost of the filters when considering energy use, changeout, and disposal costs. Its also extremely important not to skimp on access space. If an AHU is difficult to access and filters are difficult to reach, they wont get changed, and the unit will use excessive energy and underperform. Supply and return fans: Fans are the heart of any AHU and can represent a significant portion of the buildings total annual energy usage. The supply fan pushes or pulls the air through filters and coils and then distributes it through ductwork directly to spaces or to terminal boxes. Not all AHUs require a return fan, but units serving multiple spaces or using air-side economizers typically require a fan to return air to the AHU and to relieve air from the building. AHUs in which the supply fan is installed after the heating and cooling coils are referred to as draw-through units since the supply fan draws the air through the unit. In blow-through AHUs, the supply fan is located prior to the coils. This arrangement allows fan heat: which can be significantto be removed from the
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There are many types of fans applied to air handlers; the primary differences among them relate to blade configuration and whether the fan wheel is fully housed or open. The energy required for any fan is a function of the amount of air to be moved together with the air pressure the fan must generate. ASHRAE Standard 90.1-2010, Energy Standard for Buildings Except Low-Rise Residential Buildings, provides maximum fan power restrictions on HVAC systems based on the flow rate and a variety of factors related to application and filtration level. Future versions of Standard 90.1 will be incorporating a minimum fan efficiency grade (FEG) as described in AMCA 205-2010. Fans more
than 5 hp will be required to have a minimum FEG of 67 and will need to operate within 10% of their peak efficiency. (This may not apply to packaged units, which are certified in their entirety.) A critical part of any fan selection is acoustic performance. Its always important to know the maximum acceptable noise level on a project. Proper selection and specifying of fans and AHU casing can reduce the need for silencers and other costly noise mitigation techniques. Because the best way to reduce fan sound is to reduce the fan power, efficient fans frequently have the best acoustic performance. Coils: Coils are used to heat, cool, and dehumidify air. The heat source can be from hot water, steam, electric-resistance, or hot refrigerant vapor (as with a heat pump). Cooling and dehumidification can be provided via expansion of refrigerant (referred to as Direct eXpansion, or DX), or indirectly through the circulation of chilled water or glycol. In dry climates, cooling also can be effected by spray coils that reduce the dry bulb temperature of the air, but increase the airs humidity. Access: Access sections are frequently omitted from AHUs either through designer oversight or intentionally due to
Figure 4: This chart shows a breakdown of end-use energy for a large building in a hot climate as calculated from a whole-building energy simulation. Fans represent a significant portion of the total predicted annual energy use. Courtesy: H&A Architects and Engineers
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The LEED rating system requires new buildings to have at least 10% less annual energy costs than a code-compliant building.
space or budget restrictions. But skimping on access can prove shortsighted as each component within an air hander will require routine service, repair, or replacement many times over the life of the unit. Coils must be cleaned frequently to maintain proper heat transfer, and they must be accessible from front and back to do so. The more difficult it is to reach a component, the less likely maintenance will be performed, which will result in lower overall efficiency and reduced longevity. Humidifiers: There are numerous methods for delivering humidification, including steam, ultrasonic dispersion, infrared heating, and atomization of water. Careful consideration is necessary to determine which method is best suited for a given project, but humidifiers in general are maintenance intensive. They must therefore be installed in easily accessible locations since serious damage and IAQ issues can arise if humidifiers are not operating properly for extended periods.
Codes and standards
Figure 5: The curves define fan efficiency grade (FEG) as function of fan wheel diameter and a fans total peak efficiency. Note that peak total efficiency (%) can be very different than a fans FEG, especially with smaller-diameter fans. Courtesy: Air Movement and Control Association (AMCA) International Standard 205-2012
The International Building Code (IBC) and International Mechanical Code (IMC) provide requirements for, among other things, equipment location, disposal of condensate, and minimum outside air quantity. Energy efficiency requirements for individual components and packaged units are provided within the International Energy Conservation Code (IECC), ASHRAE 90.1, and California Energy
Commissions Title 24. Each state and locality determines the applicability of these codes and standards. There is significant pressure to go beyond code-minimum performance, and many mandates are in place for federal projects requiring new buildings to operate with much less energy than minimally code-compliant ones. The U.S. Green Building Councils LEED rating system requires new buildings to have at least 10% less annual energy costs than
a code-compliant building and awards points based on incremental savings above 10%. The International Green Construction Code (IgCC) and ASHRAE Standard 189.1 also tighten energy performance and are being increasingly adopted by states and localities. Multiple organizations provide standards for the testing, rating, and installation of AHUs and associated components. Some examples of these include Air Movement and Control Assn. (AMCA),
Design tips
Follow these design and troubleshooting tips when specifying air handling units (AHUs). When beginning a project, spend the time to list all the various goals and constraints including proposal requirements, applicable codes and standards, energy goals, and owner preferences. Create a matrix of each system option and document their relative strengths and weaknesses. Try hard to sell energy efficiency and maintainability at the beginning of a project. First cost is hugely important, but many owners will be willing to come up with extra money up front if they can be shown the benefits of lower total ownership costs. Consider having control dampers, electrical disconnects, and VFDs installed at the factory. More up-front coordination can be required, but the result is often a higher-quality installation and can also be less expensive when considering the savings in on-site electricians and controls contractors. Pay close attention to duct design and limit the pressure losses both inside and outside of the AHUs. Decreasing the required pressure in a fan system by just a few tenths of an inch of water can result in thousands of dollars a year in fan savings. When selecting and scheduling fans for AHUs, work closely with the AHU manufacturer to ensure that all losses associated with internal components are considered. This is especially important for plenum fans, which will have casing exit losses that can be significant. Dont forget to leave space for maintenance including the space to remove and change coils in the future. Many facilities require a clear space for service equal to the width of the AHU. Never skimp on commissioning an AHU.
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International, Air-Conditioning, Heating, and Refrigeration Institute (AHRI), ASHRAE, and Sheet Metal and Air Conditioning Contractors National Assn. (SMACNA). These organizations produce testing and rating standards that can be used by manufacturers and specifiers to gauge performance. Large institutional users typically have their own standards in addition to codes to ensure consistency and ease of maintenance for air handling equipment.
Emerging trends in AHUs
Figure 6: This is a view of supply fan array within an AHU. Fans are direct-drive plenum type. Variable frequency drives are installed at the factory. Courtesy: Buffalo Air Handling
Although much of the technology in AHUs has remained relatively unchanged for decades, some relatively new components and practices are being incorporated that can be useful in the right application. Direct-drive fans couple the fan wheel directly to the motor shaft and are typically applied with variable-frequency drives (VFD). This eliminates the drive losses associated with belts and can result in higher efficiency and lower overall noise. Fan arrays use multiple small, directdrive fans in lieu of a single large fan. Applied properly, the fan array can reduce the overall space required for the AHU while providing redundancy and energyefficient operation. Depending on the number of fans, they can be controlled in unison by one or more VFDs. Like so many other things related to AHUs, care must be taken when applying a fan array to ensure the goals of the project are met as efficiently as possible. Energy recovery is increasingly applied in AHUs and may be required by energy codes in certain applications having high percentages of outdoor air. Energy recovery enables incoming air to exchange heat and moisture with building exhaust air via desiccant-coated wheels or special materials in a flat-plate, counterflow arrangement. Successful application is dependent on many factors, most importantly climate. It is generally easiest and most cost effective to apply when dedicated outside air units are used. Dedicated outside air units are increasingly being applied in lieu of traditional air
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Every project carries with it a unique set of criteria that must be balanced to arrive at the best (not perfect) solution.
units that mix outdoor air and return air. For many climates, the toughest part of an AHUs job is treating outdoor air. Coils must be sized to handle to most extreme ambient temperatures. In humid climates, dehumidification requires air to be cooled below the mixed airs dewpoint even if the occupancy of the building might not require such low temperatures to meet space temperature setpoints. The mixing dampers and their associated control sequences in AHUs are common modes of failure, which together with sensor drift can result in over-ventilation (higher energy use) or under-ventilation (poor IAQ). A better approach for many buildings is consolidating all of the outdoor air treatment into dedicated AHUs that supply 100% outdoor air. Treated air (dehumidified or humidified) from these units can be supplied directly to occupied spaces or can be injected into mixing boxes into other AHUs dedicated to temperature control. While the addition of dedicated outdoor AHUs might at first sound like a far more expensive approach, their use may add little to the overall cost of a job as they can allow simplification of other AHUs. Condensate collection from cooling coils can save a considerable amount of water and money. The air conditioning process removes water from the air, which is then typically sent to a drain. Humid climates, including much of the eastern half of the United States, are generally good candidates for recovery of condensate. The recovered water may be collected in a cistern together with rainwater or grey water, or may be used as make-up for cooling towers. Training is also an important component of commissioning. System operators must be properly trained to understand all operating modes of each piece of equipment. Training materials must be left onsite so that new personnel can come up to speed easily.
Energy use comparison
and is located in Richmond, Va. The HVAC system is comprised of four large VAV AHUs, each supplying 32,000 cfm to single-duct terminal boxes with hot water reheat. All systems in the model are held constant except for the AHUs. The base case represents a decent AHU meeting ASHRAE 90.1 while the Alternate Case uses an improved FEG, premium efficiency motor, and a static pressure reduction of 0.5 in. wceasily achievable through careful AHU and duct system design. The results show a total energy reduction of nearly 2% for the building and an energy cost reduction of greater than 3%, which could earn the project at least one incremental LEED point for credit EA1 Optimize Energy Performance.
Conclusion
As a final note related to the energy use of AHUs, a comparative annual energy simulation was made for a typical new office building meeting or in some cases improving upon minimum prescriptive requirements of ASHRAE 90.1-2007 (see Table 1). The building is 175,000 sq ft
Table 1: Fan energy comparison: Good versus better

Base-case: ASHRAE 90.12007 compliant fan Fan efficiency grade (FEG) Fan efficiency based on wheel size and FEG Drive type Relative drive loss 1 Fan efficiency including drive loss Motor efficiency level Motor efficiency Building energy use (electrical MWh) Building energy use (gas MBtu) Fan energy use (electrical MWh) Fan energy cost Total building energy savings 2 Total building energy cost savings 2 67 63% Belt with VFD 3% 60% EPAct 93.0% 2073 1020 218.8 $18,831 Alternate: FEG = 75, reduced static pressure, direct drive 75 71% Direct with VFD 0% 71% NEMA Premium 94.1% 2008 1010 164.5 $14,085 1.8% 3.4%
The preceding information is necessarily general and is no way a comprehensive guide to proper selection and application of AHUs. Every project carries with it a unique set of criteria that must be balanced to arrive at the best (not perfect) solution. Design engineers will do well to organize these criteria early in a project and economic analysis is usually required to support the ultimate path forward. Each individual component within an AHU must be selected with a combination of research, analysis, and experience. By keeping energy efficiency and maintainability firmly in mind throughout the selection process, it is less likely there will be regrets when project is complete. Even the best AHUs and installations require a strong commitment from the buildings operators to keep them running well. Preventive maintenance programs together with continuous commissioning will help ensure the lowest possible ownership cost for any system. Rob McAtee is vice president and mechanical department head and has more than 20 years of experience in energy and building systems. Evan Riley has more than 10 years of experience in design, commissioning, and modeling of HVAC systems.
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Notes 1. Relative drive loss does not include losses related to VFD because this is constant for all cases. 2. Total building energy savings are slightly greater than fan energy savings because reduced fan energy also reduces total cooling.
Table 1: This table illustrates an energy and cost comparison between systems based on typical, but well-performing, AHUs, and a system using higher efficiency fans and reduced static pressure. Courtesy: H&A Architects and Engineers
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How to specify an indoor lighting system

By following a few guidelines, engineers and lighting designers can specify an appropriate lighting system for a facility.
By Mike Larsen, LeeD aP, Interface Engineering, Portland, Ore.
he design is complete; now its time for the luminaire schedule. Where should you start? You know that the architect wanted to use a fancy pendant luminaire in the offices and your office usually uses Brand X for the recessed 2x4. But the interior designer wanted that decorative thing for the lobby and the washrooms need that odd-looking sconce. How are you going to make sure the correct product gets bid and installed on the project? Here are some guidelines that make the task easier.
Luminaire description
Most experienced lighting designers and engineers find that the luminaire description is the key to getting the proper product. A good description leaves little doubt of the intended luminaire, while a weak description leaves the door wide open for interpretation. For example, if you want to use a recessed LED down light, which of these descriptions would produce the desired results?
Figure 1: This building, designed specifically for student athletes, includes a variety of spaces designed to focus learning efforts. In addition, public spaces include displays of athlete accomplishments and accolades. Architecture and lighting merge to reveal a multi-dimensional space. The whole building is a cohesive, colorful environment. Courtesy: Steve Cridland, Interface Engineering
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1. Architectural recessed round aperture dimmable LED down light, nominal 6-in. diameter aperture by 6.75-in.-high steel housing with extruded aluminum heat-sink matte clear reflector with convex transitional lens 2. Recessed round aperture LED down light nominal 6-in. diameter aperture with lens. Option No. 1 will take extra time, but a little additional time at the beginning of the process will save a significant amount of time when the submittals arrive at your desk. Option No. 2 means that you will be inundated with substitution requests, or when the submittal shows up, you will find that each manufacturer has several luminaires that meet your description and none of them is the one you wanted. You can, however, go too far with your description and quickly push out competition and end up breaking the budget. Using a description such as this is going to fit only one luminaire manufacturer and one model from that manufacturer: Surface mount high-intensity discharge (HID) projector 11.6-in. overall length by 4.3-in. aperture aluminum housing with 10.1-in. long aluminum yoke to provide 359 deg of rotation. Now youve created a one-manufacturer specification, which could be problematic if its a competitive bid project. A description this precise should only be used when there is only one option that meets the project requirements. Naturally this rule can be broken when it comes to white goods; those strip lights and 2x4-ft 18-cell troffers that dont require an extensive description because there arent many differences between the manufacturers. In this case a description like this provides enough information so you can be fairly certain that you will get several options that are equal in performance and price: recessed 2x4-ft lensed troffer with #12 pattern acrylic lens. If youre lighting a parking lot with 250 W Metal Halide Shoebox on 30-ft poles, several manufacturers can meet the requirements, so a generic description should suffice. Just remember to note any limitations that may exist on your project,
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Figure 2: Linear fluorescent in-wall, biax fluorescent pendants, and metal halide monopoint trackheads were used in the Richland Public Library, Richland, Wash. Courtesy: Mark Godfrey, Interface Engineering
such as house side shield in the shoe box or wire cages for your strip lights. One final note: Its easy to copy and paste from an old schedule, but if you dont review your descriptions, you might just find the 2x4-ft lensed troffer that the project needed showed up as a 2x4-ft louvered troffer.
with most things it is best to stick with what is familiar; Osram, GE, and Philips are the main competitors in the lamp market and should be considered first. If these manufactures cant meet the needs of your project, several others are waiting in the wings; Fulham and Ushio are examples. When specifying fluorescent lamps it is important to provide lamp shape, wattage, and color temperature. Telling a conLamps/LED Arent all lamps the same? No, not all tractor to provide a 32 W lamp is only lamps are created equal; theyre not even giving part of the necessary information equal among the same manufacturer. Sev- and can lead to some very strange submittals. There are 32 W eral manufacturers have fluorescent lamps availtwo or three different qualiLearning able in linear, compact, ty levels among each of the objectives and u-bend forms. Which lamp styles. Did you know Understand which lightform meets your requirethat the linear fluorescent ing type is correct for each ments? Color temperature 700 series phosphor lamps application and CRI should always be not only have lower CRI Know which energy codes listed as part of the lamp but also produce fewer pertain to the project specification or as part of lumens than the same Know how to write the specification to get the the general notes in your wattage 800 series lamps? achieved light. luminaire schedule. This Does your project require will help ensure that the good color rendering? If it does, then the 700 series lamps are not an color temperature for all the lamps on option for you, only the 800 series are. Is the project will match. There is nothing the project planning on getting any energy more embarrassing than walking through credits or rebates? Is it planning on using your project and seeing several different the low-wattage linear lamps? Does your colored lamps just to find that you didnt design take into account the lower lumen specify a color temperature. Choosing an HID lamp involves some output for the lamps? There are a lot of fluorescent lamp questions that need to be of the same considerations as choosing fluorescent lamps: shape, wattage, and asked and answered prior specification. Once you answer these and other ques- color temperature. In addition to these, tions, the selection process can begin. As think about lamp base, lamp orientation,
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Due to the potential for nonpassive failure some HID lamps are safe only in enclosed luminaires.
and color rendering. Over the past decade, manufacturers have greatly improved the color stability and color rendering of many of the popular metal halide lamps. For most of these lamps, the user can expect a color shift of only 100 K to 200 K over the life of the lampa vast improvement over options and affect the overall size of the luminaire. HID lamps have several forms and base options that require attention during specification. HID lamps are available in roughly 20 different shapes and 12 base configurations that vary depending on and the rated life. The rated life for an LED is not rated to failure like a standard lamp but to 70% of initial output (L70) and should always be noted as based on IESNA LM-80-2008.
Ballast/driver
Figure 3: In the Concordia University Library in Portland, Ore., the lighting designer specified metal halide high bay, linear fluorescent pendants, and compact fluorescent recessed downlights. Courtesy: Mark Godfrey, Interface Engineering
the 500 K to 800 K that we saw during the 1980s and 1990s. Due to this color stability, HID lamps arent just for the parking lot or warehouse anymore; they have moved inside with ceramic metal halide (CMH) options. These lamps have very stable color and perform similar to the incandescent or halogen sources. A 20 W CMH will easily replace a 50 W halogen in light output with significant energy savings, rated life, and quality of light. Many other low-wattage lamps are making their way into retail projects and office lobbies. However, that 20 W CMH lamp can be in several forms, MR16, PAR, and T4.5, which add more complexity to the selection. When using the MR or PAR style lamp, think about beam angle; the T4.5 will require additional information in the luminaire description to address the reflector distribution. Similarly, if you are illuminating a parking lot, the shape of the 400 W HID lamp will dictate the available reflector
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wattage. Be certain to review the socket information for your luminaire; more than once I have called for a medium base when the luminaire required a mogul base. Unfortunately, there is no magic formula for mogul base v medium base for wattages less than 250; above 250 W and you can be fairly certain that it will have a mogul base. A few final notes on HID lamps: Not all HID lamps can be used in horizontal and vertical orientations, and the rated life for universal burn lamps varies depending on the orientation. Make sure that your HID lamp is safe for your luminaire application. Due to the potential for nonpassive failure some HID lamps are safe only in enclosed luminaires. The process of choosing LEDs warrants an entire article unto itself (see April 2012, page 28). Here are a couple of guidelines: Check the lumens in the Illuminating Engineering Society (IES) file and make sure to pay attention to the color temperature
Ballasts are by far one of the most challenging sections of the schedule. Why? Because there are so many variables: electronic, magnetic, program start, rapid start, pulse start, low ballast factor, dimming, and more. There are many different manufacturers for each type of ballast. Visit the websites of various manufacturers to obtain information: GE, Sylvania, Philips, Fulham, Vossloh-Schwabe, Robertson, and Hatch. So where do you start? If you live in an area that has a local energy code, such as Californias Title 24 or the Oregon Energy Efficiency Specialty Code, some of the options may have been narrowed down for you. In Oregon, for example, magnetic fluorescent ballasts have been legislated out for interior lighting projects. The state also legislated out the use of probe start metal halide for certain wattage lamps.. Make certain that you review the most current code to ensure the ballast selected meets local requirements. When selecting fluorescent ballasts, the first choice typically should be NEMA Premium. By using this program as a standard, engineers can automatically narrow the search to companies with strong backgrounds in the industry and that have the collective goal of making energy-efficient products. If you are specifying compact fluorescent or T5 lamps, you cant always find the ballast necessary for your project on the NEMA list. For these lamps, it is still advisable to use the same manufacturers that are part of the NEMA program. The items that should be reviewed before making a ballast selection are ballast factor, system lumens, and input power. Ballast factor is a factor of relative light output as compared to reference ballast. Linear fluorescent ballasts are generally available in low (0.7 to 0.8), normal (0.85 to 1.0), and high (1.0+). For example, a
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Not all lamps are created equal; theyre not even equal among the same manufacturer.
normal ballast factor of 0.85 provides 85% of the lamps rated lumens; in the case of a 3100 lumen T8 lamp the lumens would be 2635. Compact fluorescent and T5/T5HO lamp ballasts have ballast factors that range from 0.88 to 1.07. Why is this important? If you have a single lamp T8 luminaire that is 50% efficient and have a normal ballast factor with a 3100 lumen T8 lamp, your luminaire is only delivering 1318 lumens. Many ballast manufactures provide some of that math for you in the form of the system lumens column in the ballast catalog. The final item is input power or how many Watts the lamp/ballast combination uses. This very important column provides accurate information for filling out energy code documentation and circuiting the lighting. When specifying dimming lights, think about the controls for the luminaire. Are they going to be 0 to 10 V? Is there a digital control system planned for the project? How the luminaires are controlled will influence your dimming options. How low do you need to dim the luminaire? It is common for T5/T5HO ballasts to dim to 1% light output, but there are only a couple of T8 dimming ballasts that can go below 5% light output, so it is important to know what is required for your project. For LED luminaires there are different levels for dimming, from those that dont dim to those that dim to 10%. Currently there are very few LED luminaires that dim below 10%, but that should be changing in the next couple of years. The dimming needs of your project should be considered when selecting an LED luminaire. A few more items to be aware of when selecting a fluorescent ballast: Some lamp/ ballast manufacturers will offer extended warranties when the lamp and ballast are from the same manufacturer. If your luminaire is controlled by occupancy sensor and is in a location that will have
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Figure 4: In this Columbia Sportswear store in Portland, Ore., the lighting designer specified linear fluorescent and ceramic metal halide monopoint trackheads. Courtesy: Mark Godfrey, Interface Engineering
several on/off cycles per day, specifying a program start ballast will help prolong the life of your lamp. A word of caution on fluorescent ballasts: Just because you specify a particular ballast doesnt mean it is going to fit in your luminaire. Not all ballast manufacturers list the housing size for their ballasts, and when they do list the size it doesnt mean the ballast will fit into the luminaire. In these cases the manufacturers representative should be able to provide ballast options that meet the project requirements and luminaire constraints. Ballasts for HID luminaires can be challenging, though not as challenging as fluorescent. There are limited options: electronic, magnetic, and magnetic pulse start. Electronic ballasts are primarily for lower wattage lamps at 20 to 150 W. These ballasts are designed to optimize
the energy performance of the system. The smaller size of this ballast allows the luminaire manufacturer to build smaller HID luminaires. Magnetic pulse start ballasts cover a wide range of lamp wattages, up to 1000 W. The Energy Independence and Security Act of 2007 (EISA), which took effect in January 2009, helped push pulse start metal halide ballasts to the forefront by legislating out the probe start metal halide lamp and ballast for wattages of 150 to 500 W. In addition, EISA pushed the manufacturer of pulse start ballasts to make the ballast more efficient for those same wattages. Today we all benefit from the legislation, not just in energy savings but also in time saved, while writing luminaire specification of metal halide systems. Magnetic probe start metal halide lamp ballasts are still available in wattages higher
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Make certain that you review the most current code to ensure the ballast selected meets local requirements.
than 1000 W and for use with 150 W lamps rated for use in wet locations. Similar to the caution noted for fluorescent ballasts, it is not uncommon to specify an HID ballast that does not fit or cannot be used in your specified luminaire.
Manufacturer information
This is the final step in a good specification, and at our firm it is the most contentious. It is important to give the electrical contractor or distributor a basis of design for the luminaire that fulfills the needs of your project. The contentious part is how much information to provide. Returning to the examplearchitectural recessed round aperture dimmable LED downlight nominal 6-in. diameter aperture by 6.75-in.-high steel housing with extruded aluminum heat-sink matte clear reflector with convex transitional lens. This description is based around Portfolios LD6x series LED recessed downlight. To this point, we have discussed the luminaire description, lamping, and ballasts, which are the major components of the luminaire. There are several options on every luminaire that we have not discussed (reflectors, lenses, finishes) because the options are project specific. This doesnt mean that they are not important, but we should assume that each luminaire schedule has sections or columns that allow engineers to specify these options.
These options are being described as part of the luminaire description matte clear reflector, and if your schedule is similar to the one our firm uses, you have a section to list the reflector, which means that this information is listed twice. Do we need to list it yet again by providing the actual catalog number in this manufacturers section? If we list it again as part of a complete catalog number (LD615D010 ERM6835 6ML1WMH), who is responsible if we get the reflector information wrong? In this case, WMH defines warm haze for the reflector finish, but what if I had typed WHH and had not noticed this error? The contractor would order wheat haze. This could be a very expensive mistake, even though I stated matte clear in the description and again in the reflector section of the schedule. The electrical contractor has a strong case to get me to share in the cost of fixing the mistake. The discussion in our firm is always how much information to provide in this last basis of design section. If we only list the series information Portfolio LD6x Series, does that provide the contractor with enough information for our intent? Many believe that if you let a contractor interpret what you want, you are destined to fail. For me, the fact that a manufacturers product specification has a disclaimer that states specifications and dimensions
subject to change without notice at the bottom of every page means that I should not provide a catalog number. This disclaimer tells me that there is a chance something in that catalog number will change between when I specify the project and when the product is ordered. This means that the electrical contractor has to interpret the designers intensions. However, with a good description, lamp, and ballast information along with the manufacturer and series number, there is very little to interpret. The designers also should review shop drawings to ensure model numbers match the description. Strong specifications start with the proper description of the desired product and are supported with the proper lamp and ballast information together with the desired manufacturer and series information. When you follow these guidelines, the proper product will be delivered to the project. Michael Larsen is an associate and senior lighting designer at Interface Engineering. His interior and exterior lighting design portfolio is extensive and includes hospitality, high-end custom homes, offices, retail, schools, and healthcare facilities. Larsen has provided lighting and daylighting design on dozens of LEED-certified projects, several of which received LEED Platinum.
Figure 5: Linear red LED and white LED area lighting are installed on angled pole on the Delta Ponds Pedestrian Bridge in Eugene, Ore. Courtesy: Mark Godfrey, Interface Engineering
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Creative use and selection of wireless devices can potentially reduce construction costs, decrease construction time, and add future flexibility to buildings.
By Michael a. culver, Pe, exp U.S. Services Inc., Maitland, Fla.
dont even use batteries and instead use energy harvesting technology. Wireless controls may fit the ticket and may even save on project construction costs and construction schedules. Wireless controls have been around for a long time, but now that wireless has become personalized (iPhone, iPad, Android), it is easy to add another level of control that is more mobile and more personalized in many cases. There are several competing wireless technologies in North America. The most prevalent are: n Clear Connect, Lutron Electronics Co. Inc., primarily 434 MHz n EnOcean, EnOcean GmbH, primarily 315 MHz n ZigBee, ZigBee Alliance, primarily 2400 MHz (2.4 GHz) n Z-Wave, Z-Wave Alliance, primarily 900 MHz Clear Connect n A registered trademark of Lutron, which licenses to other manufacturers such as AMX and Hubbell Wiring Devices. n Operates in frequency bands that do not allow devices that continuously transmit (like phones and Wi-Fi routers) and is therefore less susceptible to interference. n Operates at lower frequencies, which allows better transmission through heavy building materials. n 434 MHz in Americas; 868 MHz in Europe, Middle East, and China; 315 MHz in Japan; and 865 MHz in India. n Protocol is optimized for sending small amounts of data very quickly to many devices over a large areaprovides superior response time from devices. n Protocol is optimized for long battery life. n In market since the late 1990s.
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ant to offer your clients more for less? Then go wireless. By leveraging the flexibility of wireless control devices to handle the unpredictable futures of buildings, engineers can offer their clients more options. In todays environment of ever-changing technology and increasingly more stringent energy codes, flexibility is more valuable than ever. Many of these wireless controls use miniature batteries with a claimed life of up to 10 years; some
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Adhering to energy codes

EnOcean Trademark of EnOcean GmbH. Operates primarily on 315 MHz, (868 MHz in some areas). EnOcean Alliance agrees to a set of profiles (somewhat similar to ZigBee) and sets the application layer of the protocol. Focused on energy harvestingwireless and non-battery-powered technology. In March 2012, the EnOcean wireless standard was ratified as the international standard ISO/IEC 14543-3-10, covering the physical, access, and network layers. Used by Electronic Theatre Controls (ETC) in its Unison Aero line along with many other manufacturers. and equipment using the ZigBee standard, customers must make sure the products use the same ZigBee profile. Z-Wave Operates primarily on 900 MHz, and also 868 MHz. Mainly residential, but some light commercial applications. Z-Wave Alliance formed and many manufacturers make products that use the Z-Wave standard. To determine potential cost savings when selecting a product to be used in a building, consider looking deeper than hardware and labor costs. Many other costs can come into play when evaluating initial building and construction costs: retrofit costs, flexibility costs, and occupant comfort.
ASHRAE Standard 90.1-2010, Energy Standard for Buildings Except Low-Rise Residential Buildings, has new, very challenging requirements. According to an Oct. 19, 2011, ruling by the U.S. Dept. of Energy, all states will be required to certify that the provisions of the states commercial building codes have been updated to include the requirements of the 2010 version of Standard 90.1 standard by Oct. 18, 2013. One of the new additions to the standard is a requirement for automatic control of 15- and 20-amp receptacles in private and open offices and computer classrooms. Specifically, the standard states: 8.4.2 Automatic Receptacle Control: 125 V 15and 20-Amp receptacles, including those installed in modular partitions, installed in the following space types: a. Private offices b. Open offices c. Computer classrooms shall be controlled by an automatic control device that shall function on: a. A scheduled basis using a time-of-day operated control device that turns receptacles off at specific programmed timesan independent program schedule shall be provided for areas of no more than 25,000 sq ft but not more than one floor, or b. An occupant sensor that shall turn receptacles off within 30 minutes of all occupants leaving a space, or c. A signal from another control or alarm system that indicates the area is unoccupied.
ZigBee ZigBee is a registered trademark of the ZigBee Alliance, a non-profit association of manufacturers, which maintains the ZigBee Standard. Manufacturers have to become a Cost considerations member to make and market ZigBee prodHardware costs: Hardware costs for ucts for commercial use. items like switches, conduit, boxes, wire Operates primarily on 2.4 GHz (low voltage of 12 to 24 V and line voltage (worldwide frequency), of 120 to 277 V), occupanbut 915 MHz and 868 cy sensors/power packs, Learning MHz also available. and temperature sensors objectives Built on and uses can add up quickly. The Better understand some of physical and access layhardware costs for the the more common wireless ers of the IEEE 802.15.4 wireless devices typically technologies used in building 2003 protocol. will be greater than the controls First standardcalled costs for the wired counLearn about common wireZigBee 2004has been terparts they are replacing. less standards around since 2005 and has Soft costs: Cost savIdentify the potential cost been updated and revised ings for items like occusavings, construction efficiencies, and flexibility that several times since publipant comfort and control wireless controls can bring to cation. are harder to quantify a building The ZigBee Alliance cost-wise. However, it is sets and publishes Applinot a stretch to attribute cation Profiles to help manufacturers make occupant comfort to increased producinteroperable products, including: tivity and company retention rates. For example, consider a large, open office - ZigBee Commercial Building space with cubicles where the only perAutomation manent walls are around the perimeter of - ZigBee Home Automation the space (sometimes these are movable - ZigBee Smart Energy 1.0 walls that are part of the office furniture - ZigBee Telecommunication Sersystem; see Figure 1). It is quite common vices to place temperature sensors around the - ZigBee Health Care perimeter, hardwired in the permanent - ZigBee RF4CE - Remote Control It is important to note that to ensure walls. In many cases, temperature seninteroperability between various devices sors for different zones are placed on the
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wall next to each other to help save on construction costs. But when a temperature sensor is not located in the zone that the HVAC system serves, inaccurate temperature sensing can result in the actual location where the HVAC unit is providing cooling/heating. Moreover, when the temperature sensors are ganged together on the wall, often there is confusion as to which temperature sensor controls which area. Wireless temperature sensors can easily be located at the point of use, even on a movable wall or on a partition within an employees cubicle. Lighting controls with dimming and personal control at each workstation also help to improve employee comfort and productivity. Employee comfort has a definite correlation to productivity and retention rates for companies, as shown in a white paper
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By leveraging the flexibility of wireless control devices, engineers can offer their clients more options.
titled Environmental Satisfaction, Personal Control, and the Positive Correlation to Increased Productivity prepared by Carol Lomonaco and Dennis Miller from Johnson Controls Inc. This study indicates that giving employees control over their comfort gave nearly a 3% productivity boost. Furthermore, according to this white paper, indoor air quality (IAQ) and comfort has up to a 60% impact on productivity levels. Other studies indicate that the cost per square foot of salaries in an average facility is anywhere from 8 to 13 times the cost per square foot of building operations, often topping $200 per square foot, per person, per year. It is easy to correlate the significance of employee comfort costs as compared to a buildings operating costs because the employee costs are significantly higher. Flexibility: Flexibility cost savings can be encountered not only during but also long after the construction of a new building. During new construction, it is quite common for the building design to morph due to construction conflicts or owner directed changes to the design. These changes often lead to material and labor waste because walls are sometimes relocated or devices have to be roughed in again and rewired. After the building is constructed, there might be a need for additions, moves, and changes, or complete building or space renovations. Wireless devices rarely get in the way because they are easily removed with two screws and in some cases peel-and-stick adhesive strips. Relocation of these devices is measured in minutes, not hours, and does not require skilled labor in most cases. Construction schedules: During new construction or renovations, maintaining a construction schedule can prove to be very challenging. Scheduling the various trades to rough-in conduit and boxes prior to installing drywall does not always go as planned. In successful building construction, many hours can be spent on coordinating these rough-ins so that they dont conflict with doors and furniture. Because no conduit or boxes are required, wireless solutions can reduce the coordination time during the rough-in phase and thus speed up construction. Because wireless devices are installed near the end of construction, each device location is touched only once for the final installation. Additionally, in the case of temperature sensors, the HVAC contractor does not have to wire the low-voltage wiring and then return at a later date to install and terminate the wire in the sensor. As wireless technologies become more commonplace in building construction and renovation, schedules can be impacted in a positive manner, creating a win-win situation for the contractors and building owners. Labor savings: Similar to construction schedule cost savings, significant labor savings costs can be reaped by owners and
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Casino expansion goes wireless
n the Great Smoky Mountains National Park in North Carolina, the Harrahs Cherokee Casino and Hotel has almost completed a world-class expansion project worth more than $500 million. The 985,000 square foot expansion, due to be 100% completed before the end of the year (first phase of this expansion opened June 2010), included a new third hotel tower, 3000-seat events center, a significant expansion of the casino area, and a high-end luxury spa. As one can imagine, the last thing the public space designers wanted to deal with was controls conduits flying over, under, and on the highly themed finishes in the public spaces. exp and Trane worked together to find a solution that not only solved the conduit challenges, but also saved the project both time and money. The wireless sensor solution required that the normal controllers in each HVAC unit, terminal box, etc., incorporate a controller with a wireless receiver. Each controller/receiver combination can easily communicate wirelessly to sensors throughout the space within a 200 ft radius. (The dedicated wireless receiver per HVAC unit provides redundancy and eliminates the chance of one receiver failure affecting the control of multiple HVAC units, plus it adds local communication at the controller directly to the wireless receiver.) The new construction and expansion used roughly 870 of Tranes WTS series wireless temperature sensors with an estimated installed cost savings to the project of roughly $106,000. This does not include any additional cost savings from devices that were easily relocated without having to rewire, therefore reducing construction change orders. This project involved many phases of construction to keep the existing facility in operation and maximize the amount of gaming floor in operation at all times. This resulted in fast construction for each phase, which made the choice to go with a wireless solution very beneficial.
Figure 2: The wireless temperature sensor can be used in environments where occupants are not allowed any local control of the occupied space. The WZS wireless zone sensor allows occupants limited local control of temperature settings and the ability to override the systems settings at any given time as space becomes occupied or unoccupied. The wireless display sensor is a configurable sensor gives occupants total control over their environment, along with a display that quickly conveys current space conditions and operating modes. Courtesy: Trane, a brand of Ingersoll Rand
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contractors for many of the same reasons. It is estimated that wireless devices can save up to 50% of physical labor costs. This can be translated into reduced project costs and increased contractor efficiency because fewer workers are required to be on-site. Labor savings could vary drastically depending on whether local codes require the low-voltage wiring in conduit or whether labor rates reflect union versus non-union areas. Design and engineering costs: Other than having to pay attention to building construction types and the effect they have on distances between receivers/repeaters and the wireless transmitters (i.e., switches, sensors, etc.), there is little impact, positive or negative, to the design engineer when using wireless products. Once the devices are incorporated into the design specifications, the only impact on design might be fewer wiring details. However, engineers should consider buildings with special construction where a radio frequency (RF) study may be warranted to ensure proper wireless penetration.
Conclusion
and how well the contractors are educated on the efficiencies of using of wireless technologies. For medium to large projects, Trane reports that its wireless solution is priced to save an average of 10% of the installed price compared to a traditional wired solution. This does not include the soft or flexibility costs that can be further achieved throughout the buildings lifecycle. Lutron, for example, has reported that on a recent project in New York City, the devices that were shifted from wired to wireless took 70% less installed cost (labor and materials). The overall project, including fixtures and other wireless controls, achieved 17% savings over a wired equivalent. In individual office spaces with a switch and occupancy/vacancy sensors, the cost savings can be in the range of 20% ($15 to $60 per office, depending on the labor rates). The higher the labor rate, the better the savings.
With the world going more wireless every day, the cut the cord statement continually loosens and morphs from the cable TV and phone industries to almost any device category you can think of. As wireless technologies continue to evolve and are incorporated into more devices, it will be more important to understand the cost savings and other benefits during the bidding process. Building owners, design engineers, and contractors all will benefit from the increased efficiencies, cost savings, and flexibility that wireless devices offer. Michael A. Culver is a principal at exp U.S. Services where he focuses on technical specifications and building designs in the hospitality, entertainment, and mission critical fields.
When the traditional hardwired system approach is compared to a wireless approach, accounting for all wireless hardware costs and all other cost savings, the overall installed cost for a wireless solution is comparable or even less than that for a wired system. Consideration should also be given to some of the maintenance costs of wireless sensors as compared to hardwired counterparts. Many wireless sensors require battery replacement; some replacement schedules are as long as 10 years. The maintenance cost of replacing the batteries in hundreds or even thousands of wireless sensors in a facility is not negligible. Sensor failure due to a low battery or signal fade or loss could compromise occupant safety or equipment/property damage. Risk and reliability may also be considerations. There may be buildings where this risk is not feasible. Cost savings will always vary based on the project type, local labor rates,
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Commissioning control systems for MCFs

Controls success starts in design with clear requirements, and ends with thorough testing and complete turnover. Here are eight steps to follow.
By James mcenteggart, Pe, Primary Integration Solutions LLC, Charlotte, N.C.
he phrase integrated MEP control systems generates images of holistic design where all components of the mechanical, electrical, plumbing (MEP), and fire protection systems work in harmony. Unfortunately, industry professionals see far too many mission critical facilities (MCFs) in which MEP systems are joined by a menagerie of control systems and protocols with varying degrees of success. Successful integration of MEP control systems depends as much on effective independent commissioning as it does on the right design and proper implementation. Experienced commissioning agents (CxAs) do not claim to be design experts; however, they have seen many integrated MEP control systems that did not perform as designed during testing and commissioning. When commissioning begins at the planning phase of a project, the questions and insights gained from experience in commissioning MCFs contribute the greatest value to meeting project objectives and saving the owner and project team rework, change orders, and associated time and
Figure 1: The process for testing and commissioning any system should start at the component level and expand in scope until the entire system, and ultimately the whole facility, is tested. Courtesy: Primary Integration Solutions
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money. Here are eight key issues and insights at each phase of an MEP control integration project.
2. Multisystem automation provides the most flexibility.

At the core, there are two ways to integrate multiple systems: select a single controls and automation vendor and make it responsible for all aspects of the integration, or use a third-party integration system to connect the various systems, process the data, and present it in a uniform manner. From experience, a CxA may urge use of a third-party integrator. Although the single-source solution has the advantage of ease of initial implementation and a single point of responsibility to resolve problems, the main drawback is that once a single vendor is in place, purchasing power is severely compromised. Switching controls vendors in an operating facility is costly and disruptive. The third-party integrator introduces another vendor to the project, but provides the most flexibility for the owners future system modifications and upgrades. It also has the benefit of fully leveraging the controls and automation that are supplied by the manufacturers of most building equipment. With the continuing development in automation protocols, the differences between the two approaches has diminished, but not disappeared. A CxA may also advise bringing to the planning table a third-party integration consultant. To ensure objectivity, specify that the consultant is ineligible to bid the implementation contract.
1. Develop a clear, written statement

of operational and performance goals. From commissioning experience, there are two critical success factors in the planning phase of an MEP control integration project: a concise written definition of project goals in operational and performance terms; and the right decisions about multi- versus single-system automation and network architecture. It is surprising how often project teams assume that the goals of the project are clear to all participants without clearly defining them in a written document. The CxA can help the team define the project goals in as much detail as possible, and put them in a concise, written owners project requirements (OPR) document. The document should identify and define the owners operational and performance objectives in detail. For example, operational details might include the owners requirement for real-time communication of system operating data to staff of a remote, 24/7 network operations center. The owners performance goals might, for example, include key parameters such as refresh time for data reporting. Vetting the requirements through the clients IT department for security requirements at this stage will save headaches in the future. The document should be periodically reviewed over the course of the project, and key decisions that inevitably impact design and implementation of the project should also be documented. A CxA can also help to get everyone literally on the same page by summarizing the typical 100-plus-page program document into a concise 10-page document that outlines the specific project requirements, including setpoints, required redundancy, and so on. The agent also uses this summary document to review design to ensure it remains true to the project goals.
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connected systems. Often, the standard Ethernet network hardware is inadequate for MEP control data, and this becomes obvious at testing and commissioning. Over the past year, one CxA saw weeks of lost time in a number of projects due to the need to resolve issues related to single-system automation and singlenetwork architecture. Time and money would have been saved had the potential drawbacks been anticipated by all members of the team in the planning phase.
4. Design/specification: Leave no room for multiple interpretations.

The proper design and specification is the most critical component in delivering a fully integrated MEP control system in a cost-effective manner. Having a hands-on experienced system integration consultant on the design team is usually money well spent. The participation of this profession will ensure that design and specifications are practical, economical, and, most importantly, achievable. Equally important is development of a specification that leaves no room for interpretation. The CxA can be invaluable in helping to ensure that the specs are clear, concise, and detailed to avoid the misinterpretations that can lead to change orders at the testing and commissioning phaseor worse, disagreements that lead to litigation. As the system design takes shape, the underlying concepts should be simple and easy to understand. If necessary, the concepts should be broken into smaller components until they can be easily explained to any programmer, system integrator, installer, or operator. Simplification of the concepts to their core elements ensures that the development of control sequences will be clear and easy to understand. Similarly, the mark of high-quality MEP control system construction documents is a singular meaning. Leave no room for multiple interpretations. Ideally, invite both experienced industry professionals and stakeholders, such as
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3. Network architecture: Two networks are better than one.

Historically, MEP control and automation networks were set up on a dedicated network infrastructure physically separated from the production IT network. As protocol translation technology has improved, the industry has increasingly relied on a shared Ethernet infrastructure for IT and MEP control systems. This saves money; however, the design of the active network components in this shared network must accommodate the protocols and data types being carried by all
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Successful integration of MEP control systems depends on effective independent commissioning and proper implementation.
the MEP operators, to review the documents for completeness and singular meaning. creation and use of small, standard reusable blocks of code, which will reduce total programming time and troubleshooting requirements in the field. No project can be delivered without some level of customization, but the standard blocks should be the starting point, with all modifications and additions tracked in a version control system that supports restoration of the stored code to various points in the development so the program can revert to a state when it was known to function. This functionality reduces the level of effort to manage future updates and code enhancements. Project specifications should require the controls vendor to submit a complete control graphics screen map and mockups for the facilitys staff to review and accept before code development begins in earnest. This enables the initial development of the code to more closely meet final requirements on the initial pass, saving rework and time later. Similarly, specify that the controls contractor require from each manufacturer a detailed index of all their control points and how they are accessed via standard protocols. This information should be cataloged into a master points list that is used for network planning, as well as development of the control sequences. The CxA will validate that the control graphics screen map and protocol map meet the clients requirements.
5. Avoid software issues related to control code, graphics, and protocol mapping.
MEP control system vendors general approach to the development of control code is to have a single or small group of programmers prepare the code based upon the project documents and the programmers own approach. From experience as a CxA, this approach creates multiple opportunities for problems during implementation and throughout the entire lifecycle of the system. Ideally, criteria for control system vendor selection should include the
6. Implementation: Factory testing saves time.
Figure 2: As the system design takes shape, the underlying concepts should be simple and easy to understand. An integration map, such as this sample, clearly differentiates the integrated and non-integrated equipment controls, identifies the types of system communications, and highlights key revisions to the plan. Courtesy: Primary Integration Solutions
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Some CxAs strongly recommend factory testing, which has gained some traction in the industry but is still underused. Requiring the controls and automation contractor to assemble its panels in the shop and complete programming and code development prior to deployment of equipment in the field can shave a great deal of time off the project delivery schedule when it is most valuable: at the end of the project just prior to turnover. Typically, the engineer will specify that the test must be performed, and the manufacturer will write the test procedure. The engineer and CxA should review the procedure prior to testing. Schedule the factory acceptance test to allow the engineer, CxA, and facilitys operations staff to assess the graphics and operator interface and review the modes of operation (including presentation of alarms). The test should be conducted to the greatest extent possible by using the actual hardware that will be deployed to the project. The CxA witnesses the testing process and validates the results. Identifying issues in the shop and getting user feedback before delivery to the site reduces field modifications and the potential errors that they introduce.
Figure 3: Verification of all original equipment manufacturer (OEM) controls at each device is a prerequisite of any integration testing. Courtesy: Primary Integration Solutions
7. On-site testing and commissioning starts at the component level.

The process for testing and commissioning any system should start at the component level and expand in scope until the entire system, and ultimately the whole facility, is tested. By their nature the full implementation of integrated controls will be one of the last items on the schedule; however, this does not relieve the installer from completing proper testing of all installed components via pointto-point verification and loop checks. A key concept that is not well understood in the industry is the term done. All too often a CxA receives a status report that something is done, only to find that several key components, such as power connections, are unfinished.
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This wastes time, and mission critical projects rarely have the luxury of wasted time. Before testing the integration of systems, the constituent systems themselves must be completed: that is, all open items are closed, and a complete, successful start-up has been documented. One way to streamline project delivery and avoid increasing project costs over time is for engineers to contractually require that contractors pay for the CxAs additional time resulting from misreporting completion status. Here is the recommended commissioning process from the component to system level: n Original equipment manufacturer (OEM) controls: Verification of all OEM controls at each device is a prerequisite of any integration testing. n Protocol transfer tests: Standard tests should be used to confirm proper configuration of the network infrastructure to support each of the protocols being used. Special care must be taken to test the robustness of the infrastructure to handle both normal and abnormal traffic levels.
n Silo system testing: Similarly, systems that have control systems installed by the controls contractor should have comprehensive testing done on all points to ensure proper connections and configuration within the control system. Some CxAs try to combine OEM and silo system testing; these should be conducted for each component and then for the overall integration. n System-to-system tests: Once all subsystems and components have been successfully tested, the commissioning program can move into the integrated system testing phase. At this point each component system has been fully tested in a stand-alone fashion, so integrated testing does not need to cover the same ground. Rather the focus should be on the interfaces between systems; for instance, the interaction between the fire detection systems and the HVAC systems. Each scenario that requires that two or more systems operate in a unified manner should be simulated and appropriate response verified. Inviting facility staff to participate in these tests is an excellent opportunity for the CxA to provide training.
8. Ongoing operation/change control: Specify a complete, updated set of documents.

Upon successful completion of the construction and acceptance testing, the facility is ready to be turned over. As part of the turnover, the contractor should provide a complete set of updated documents and control code. A lessons-learned session that includes the construction, commissioning, and operating staff yields significant knowledge transfer to support ongoing operations. In addition, having the controls contractor periodically return to the site (monthly or quarterly) to work with the facility staff on small system adjustments is a good way to ensure that facility operations remain optimized. Changes in setpoints or programming should be updated in the documents.
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Periodic retesting provides a level of assurance that the systems performance has not degraded over time.
As time progresses and the various suppliers issue updates to the on-board controllers or system software, great care must be taken to determine the impact the upgrade will have on the integrated control and automation system. Advise owners to make all service technicians aware that a formal review must be undertaken before any firmware or software upgrades can be installed at the site. Manufacturers that supply heavily to the mission critical industry are familiar with this requirement and often issue full briefings on the upgrades they issue. However, owners should be made aware that equipment suppliers that deal across a broader scope of industries may not be familiar with this requirement and will require some direct interaction. The details of the upgrade should be reviewed by someone with in-depth knowledge of the control system to identify possible impacts. Finally, periodic retesting and recommissioning of the controls and integration during scheduled maintenance windows will provide a level of assurance that the systems performance has not degraded over time. CxAs can provide this relatively low-cost, high-value service over the lifecycle of the system. The integration of MEP control systems in a mission critical facility is an exacting and demanding task. Careful and deliberate planning, coupled with professional installation, testing, and commissioning, is the only way to achieve a successful outcome. Assembling a team with controls integration and commissioning experience in the planning phase of a project will yield substantial benefits in avoided costs and improved schedule. James McEnteggart is vice president of Primary Integration Solutions, a mission critical commissioning firm. He has more than 20 years of experience in MEP design and commissioning for mission critical and healthcare facilities.
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Molded case circuit breakers

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inside
on the cover
Most large industrial buildings benet from supplemental heating units fueled with clean, efcient and affordable natural gas. Photos courtesy Modine Manufacturing and Johnson Air Rotation.
Gas Technology is a trademark of Energy Solutions Center Inc. and is published in cooperation with CFE Media, LLC. Gas Technology is an educational supplement from: Energy Solutions Center Inc. 400 N. Capitol St., N.W. Washington, DC 20001 (202) 824-7150 www.energysolutionscenter.org David Weiss, Executive Director Jake Delwiche Contributing Editor Comments may be directed to: Gas Technology Editor Plant Engineering Magazine 1111 W. 22nd Street, Ste. 250 Oak Brook, IL 60523 (630) 571-4070 Printed in the USA
Supplemental Heat for Industrial Buildings. The right equipment can maintain proper building pressurization, comfortable working conditions, air mixing for improved ef ciency, and added spot heat near high heat loss points.
A6 Natural Gas Vehicle Fueling
The CNG fueling infrastructure is blossoming and beneficiaries include industrial, commercial and transportation companies that operate road vehicles of all kinds. Find out if theres a place for natural gas vehicle fueling in your future.
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A10 Microturbine Technology in Todays

Energy World Small gas turbines in sizes up to 250kW can provide both economical electric power and process or comfort heat for industrial and institutional energy users.
energy solutions center websites

www.aircompressor.org www.cleanboiler.org www.energysolutionscenter.org www.naturalgasefciency.org www.gasairconditioning.org www.poweronsite.org
A8 Infrared Imaging on Your Audit Team

Todays point and shoot infrared cameras are more accurate and easier to use than ever before. With proper training, in-house audit teams can use these valuable tools to spot mechanical and electrical problems, areas of energy waste, and can protect building thermal integrity.
A12 Keep Your Boiler Plant at Its Peak

Modern gas-fired boilers are marvels of control and efficiency. Be sure your boiler plant is running the way it should with regular inspections, combustion efficiency testing, and programming to operate all units at their sweet spot for efficiency.
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Supplementary Heat for Industrial Spaces

TODAYS INDUSTRIAL OR WAREHOUSE SPACES are different from other comfort conditioning applications. These buildings typically have high ceilings and may have large ventilation requirements. Depending on the geographic location and the processes within the building, the building heat requirement may be large or modest, but industrial buildings in all but the warmest climates require some heat for at least part of the year. The building primary heating system could be furnaces, air heaters, radiant oors, a steam hydronic system, or even byproduct hydronic heat from process hot water.
Systems Improve Ef ciency, Add Comfort
ufacturing or food processes and may also be detrimental to employee health. A challenge in maintaining correct pressurization is that building pressure levels can change rapidly with ventilation units being cycled, or large doors being opened.
Makeup Air Heating Needed

When neither heating or cooling are required, problems with negative building pressures may be relieved simply by leaving open large doors, or by continuous operation of propeller fans to supply makeup outdoor air. During the heating season, these solutions wont work, at least if building comfort and ef ciency are issues. The best solution is often the use of air handlers with natural gas- red heating to supply ltered building makeup air. Makeup air handlers commonly have heaters that are either directred or indirect- red. Direct- red units are more common. These are usually installed on a rooftop, but can be free-standing next to the building on a pad or elevated platform. Vertical makeup units are sometimes mounted on an exterior wall. Makeup air handlers are designed to provide variable volumes of pre-heated ltered outdoor air to the building to offset ventilation losses and building leakage.
Keeping It Positive
Most industrial buildings can bene t from supplementary heating and air ow equipment. An issue for many facilities is maintaining correct building pressurization. Todays stringent industrial ventilation requirements can result in a partial vacuum in the building. If there are open- ame processes in the building such as welding, brazing, ovens, boilers or heat-treating equipment, then negative building pressures can create problems. A partial vacuum could affect ame stability and the ability to maintain exhaust ows. Another issue with negative pressure is that building doors become dif cult to open or control, and this may be a safety hazard. Further, negative pressures will draw unltered outdoor air into the building that may contaminate manRooftop makeup air handlers with direct firing are available in a wide range of sizes and can be matched to the makeup air requirements of most industrial buildings. Photo courtesy Cambridge Engineering
Match Flows to Demand

Usually makeup air heating units are a draw-thru design, that is, the blower is downstream from the heating section. Some units use a variable-frequency drive (VFD) on the blower to allow the unit to modulate air ow to match building ventilation rates, or match a set building air pressure.
gastechnology / WINTER 12
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Cutaway view of the heating function in a direct-fired rooftop makeup air handler. Illustration courtesy Four Seasons Controlled Climates Ltd.
air systems. This approach allows energy ef ciency technologies to be more cost effectively applied while delivering improved facility operations. Units can be controlled on both a temperature and a building pressure basis to assure maximum comfort and ef ciency. The heaters can either be non-ducted or ducted. Ducted air handler outlets are sometimes used to deliver heated air to lower levels or to more distant parts of the building that need extra heat. Generally the directred heaters are available in the larger capacities up to 100,000 cfm and sometimes more. Commonly the design temperature rise is approximately 60 to 75 F. Because of the greater weight of indirect- red units, you may need to install special structural supports for such units in rooftop installations.
Advantages to Direct-Fired
For units that will operate year-round, packages are also available with cooling/ dehumidi cation coils as well as heating sections. This type unit is widely used with facilities such as food processing, wastewater treatment and other industries where it is important to maintain building pressures and control the indoor environment at all times. Douglas Kosar is an engineer with the Gas Technology Institute, specializing in building energy ef ciency. He indicates that for industrial spaces, makeup air handlers are especially important. They reduce in ltration of cold outdoor air and drafts through open doors, i.e., if negative building pressure and resulting in ltration is allowed it can defeat proper operation of air curtains at large shipping/receiving doors. Further, they can promote proper operation of exhaust systems. a requirement as well in industrial facilities that must maintain speci c temperature and humidity ranges for manufacturing processes such as food and beverage, or pharmaceuticals. To install the correct size makeup air system, Kosar says, it is necessary to add up all the exhaust equipment to determine the makeup air requirement, plus ventilation air for workers, and a little extra for some positive pressurization. That air ow combined with the needed temperature rise from winter design air temperature will determine the heating capacity. According to John Szymanski from Trane, a supplier of such equipment, the direct-
Warehouses are Different

Kosar points out that warehouse spaces generally have much lower required exhaust ows. But bonded warehouses may be required to maintain speci c temperature and humidity ranges and should employ controlled tempered introduction of any needed makeup/ventilation air. This can be
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Focus on Speci c Need

Kosar points out that in designing new facilities or retro tting existing facilities, owners should consider isolating outdoor air treatment to a limited number of specialized, dedicated outdoor
Most air turnover units are available with plenum extensions to reach to the ceilings of industrial buildings. Photo courtesy Johnson Air Rotation.
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CAMBRIDGE ENGINEERING www.cambridge-eng.com GAS TECHNOLOGY INSTITUTE www.gastechnology.org
GREENHECK www.greenheck.com JOHNSON AIR ROTATION johnsonairrotation.com
MODINE MANUFACTURING COMPANY www.modinehvac.com REZNOR www.rezspec.com
TRANE www.trane.com
red models provide lower rst cost and a smaller footprint. He adds, Because they also have a lower internal static pressure, a smaller blower is required. According to Szymanski, the directred units can also be ordered in a vertical arrangement. This can assist in air turnover for structures with large oor to ceiling height like warehouses and heavy manufacturing. For spaces where outdoor air makeup is not a primary requirement, another solution to improve building comfort is dedicated air turnover units, sometimes called air rotation units. These oor-mounted indoor or outdoor units are designed to overcome inef ciencies caused by air strati cation in high-ceiling spaces. They add to building comfort by adding primary or supplementary heating and cooling. In a high industrial or warehouse space without air rotation, ceiling level air temperatures can be as much as 25 degrees higher than at the oor level.
Unit Heaters for Spot Comfort

Unit heaters are available in either directred or indirect- red styles. For maximum operating ef ciency with indirect ring, Modine Manufacturing offers its Ef nity93 Model PTC which features a four-pass heat exchanger. The nal pass is a condensing coil to extract the maximum heat from the combustion gases. Units are available in sizes from 55,000 to 310,000 BTU/hr all operating at 93% ef ciency. Because it is a condensing unit, it is necessary to pipe condensate to a plant drain. In addition to these three approaches makeup air heaters, air turnover units and unit heaters there are specialty gas- red heating products such as gas infrared heaters and gas- red heated air knives for installation at large open doorways. In all cases, owners enjoy the bene ts of gas space heating at fuel costs that are highly attrac-
tive compared to the other alternatives oil, propane or resistance electric heat.
Natural Gas a Natural Choice

To achieve a comfortable and ef cient industrial environment, it is usually necessary to offset exhaust air ows with makeup air handlers. Air turnover devices assure more even distribution of heat in high-ceiling spaces, and improve overall heating ef ciency. Specialty devices such as unit heaters, heated air knives, and gas infrared heaters improve comfort levels in high heat loss areas. For all of these applications, natural gas is the preferred energy source because it is clean, safe, ef cient and affordable. Your engineer can help you improve building comfort and actually reduce heating expense by installing the right kind of supplementary heating equipment. GT
Mixing is the Key

In heating mode, these units draw in air near the oor level and pass it over heating sections as needed and direct it upward in the tall plenum, which can be extended as needed to reach even very high ceilings. Warmed low-velocity conditioned air exits at ceiling level and spreads across the ceiling level, slowly tumbling down the sidewalls. This causes room air to mix and oor level temperatures become much closer to those at the ceiling. In this way, thermostat levels can be set much lower to achieve the same level of comfort, and signi cant energy is conserved. A third approach that is widely used in spot industrial applications is unit heaters. These are compact high output units using gas heating with high-velocity air distribution by either propeller or centrifugal fans. Unit heaters are a common solution near high heat-loss areas such as loading docks or openings to unheated warehouse space.
Unit heaters are available in a wide range of sizes and can be either directly or indirectly fired. Photo courtesy Modine Manufacturing.
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Infrastructure Developing to Meet Demand

A DYNAMIC CHANGE in vehicle fuels in North America is happening right now the wide-spread adoption of natural gas as a vehicle fuel. Weve long understood its potential. Now the change is underway. Dissatisfaction with high gasoline and diesel fuel costs abound.
Natural Gas Vehicles on the Rise

qualify locations for CNG fueling, we evaluate local energy users who might convert to CNG usage. He feels that key users might be refuse haulers, ready-mix concrete rms or regional haulers.
was recently a presenter at a Technology & Market Assessment Forum sponsored by the Energy Solutions Center. Kwik Trip operates the rst alternative fuels fueling station in the U.S., offering access to propane, biodiesel, E-85, electric vehicle charging, LNG and CNG.
Certain Users Obvious Winners

Typically these are operators of low-mpg vehicles that put on considerable annual mileage and return to a home station at night. If they are relatively small operations, or if they are just getting into CNG, they may not want the immediate expense or uncertainty of a dedicated fueling operation. Thats where we come in. We will offer a fast- ll capability in a convenient location and we can get them started on CNG. Hirschboeck notes that Kwik Trip itself operates a eet of 150 heavy-duty road trucks and an additional 100 light-duty trucks and cars. Currently the company is operating 24 vehicles on CNG, with 14 more on order and an additional 11 vehicles planned for spring delivery. He explains that the acceptance of the CNG ve-
Problems with Petroleum

Today about 50% of U.S. crude oil comes from sources outside of the U.S. or Canada. This compares with U.S. natural gas supplies, 98% of which are currently from the U.S. or Canada. Further, gasoline and diesel have emission problems with NOx, particulates and VOCs. Diesel engines in particular are often noisy. These fuels are expensive and promise to remain so into the inde nite future. With burgeoning production of natural gas using new drilling technologies, the price of compressed natural gas (CNG) on a gallon-of-gasoline-equivalent (GGE) basis is increasingly attractive. Industrial and commercial operators of road vehicles with signi cant daily mileage requirements have discovered CNG and in some cases liquid natural gas (LNG) as the fuel of choice for now and for the future. Retailers are typically selling CNG at a price well below $2 per GGE.
Full Range of Fuel Options

Hollett indicated, Kwik Trip is committed to developing a functional natural gas infrastructure in Wisconsin, Minnesota and Iowa. He notes that the company has already developed two natural gas fueling sites in La Crosse, Wisconsin and one each in Sturdevant, Wisconsin (near Milwaukee) and in Rochester, Minnesota. As many as a dozen more sites, mostly along Interstate Highway routes, are currently under study for CNG fueling development. Kwik Trips Alternative Fuels Superintendent Joel Hirschboeck emphasizes the companys focus on development of a functional infrastructure. We see great potential for this as a motor fuel. As we
Vehicles such as this City of Milwaukee refuse truck that have high annual mileage and low mpg are ideal candidates for time-fill fueling with CNG.
Infrastructure Under Construction

The infrastructure for refueling is developing. Take the example of a retailer that is enthusiastic about the future of natural gas as a motor fuel Kwik Trip Inc., a privately-held rm headquartered in La Crosse, Wisconsin with over 400 convenience stores and travel centers in Wisconsin, Minnesota and Iowa. Kwik Trip representative Chad Hollett
A6 gastechnology / WINTER 12 WWW.ENERGYSOLUTIONSCENTER.ORG
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hicles by drivers has been excellent. The 8.9 CNG liter truck engine we use is relatively small and it pulls loads of 65,000 lbs and more. But the drivers have adjusted to CNG and like it. They notice that that it is significantly quieter and it doesnt leave an oily diesel smell on their clothes. And they like the idea of using a domestic fuel resource. They feel good about that.
tion may be an in-house time-fill refueling station. For operators that have less predictable fueling needs, the best solution may be an on-site fast fill facility, or using a public facility. Currently there are approximately 525 public CNG fast-fill facilities in the U.S., with many more planned or under study. Public facilities are particularly abundant in California, Oklahoma, and Utah. Susan Davis from Questar Corporation was a recent presenter at a Technology & Market Assessment Forum. Questar in Utah is one of the national utility leaders in encouraging and sponsoring the development of natural gas vehicles. Davis explained that the company feels infrastructure development is one of the keys to a successful national adoption of natural gas vehicle use.
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DOE AltErnAtE FuEls DAtA CEntEr www.afdc.energy.gov/locator/stations KwiK trip www.kwiktrip.com nAturAl GAs VEhiClEs FOr AmEriCA www.ngvc.org QuEstAr FuElinG www.questarfueling.com
Questar Fueling has worked with the State of Utah and other private developers in building fueling infrastructure along the I-15 corridor in Utah. Photo courtesy Questar Fueling. From the companys perspective, the biggest attraction is significantly lower fuel cost per ton-mile. Hirschboeck adds that because there are fewer residual combustion byproducts, engines stay cleaner and lubricating oils last longer. Further, with future diesel engines, more expensive fuel treatment and emission controls will be required.
I-15 Corridor in Utah

In Utah, there are 72 natural fueling stations, including 27 operated by Questar and available for public use. Others are operated by the State of Utah, and by other private owners. The I-15 corridor from north to south through Utah is dotted with many fueling stations, making inter-city transportation by natural gas vehicles possible. Davis indicated that Questar Corporation recently created a non-regulated subsidiary called Questar Fueling with a mission of developing natural gas fueling with a national scope. The firm offers consultation, design, installation and leasing for natural gas fueling stations, both public and private. Judd Cook is Director, Business Development for Questar Fueling. He says that the I-15 corridor experience shows the growth potential of natural gas for transportation. Cook says, We have seen just under a 20% increase in sales volumes this year over the same period last year. Vehicle operators have begun to understand the potential.
the growing interest in natural gas fuels. Many of the customers we are working with in the heavy duty market are currently seeing paybacks between 14 and 18 months. He believes paybacks of two to three years or less will incent users to convert or purchase new vehicles. Interest in CNG fueling is growing. Cook says, We are currently working with several of the nations largest trucking companies who are testing natural gas vehicles.
Consider the Natural Gas Option

Whether your business is inter-city trucking or local delivery, refuse pickup or ready mix delivery, school busing or parts expediting, theres a good chance that natural gas should be in your vehicle planning cycle. There are many organizations that can help you do the evaluation. But before you commit to buying your next diesel or gasoline vehicle, consider the third choice natural gas. GT
Short Payback
Similarly, with light duty vehicles, for Kwik Trip the first attraction is also lower fuel cost. Hirschboeck says, If you are operating a light-duty vehicle 25,000 to 30,000 miles per year the payback is very short less than two years. According to Natural Gas Vehicles for America (NGVA), there are more than 120,000 natural gas vehicles operating in the U.S. today, and more than 15.2 million worldwide. This includes more than 11,000 transit buses, 4,000 refuse trucks, 3,000 school buses, about 17,000 medium duty vehicles such as airport shuttles, and more than 30,000 light duty vehicles. There is also a growing use of natural gas fueling for heavy-duty over-the-road trucks.
Roles for Both Public and Private Sites

For some fleet operators the best fueling opwww.energySolutionScenter.org
Short Paybacks Encourage Transitions

Cook credits the obvious savings in fuel costs for fleet operators for
Kwik Trip has committed to natural gas fueling for additions to its fleet of trucks and light-duty vehicles. The company is also developing a network of alternate fueling stations in Wisconsin, Minnesota and Iowa.
gastechnology / winter 12
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11/23/2012 1:33:43 PM
Use Infrared Imaging

With Training, You Can Do It Yourself
WITH INFRARED CAMERA prices dropping and their capabilities increasing, many large energy users are considering doing their own infrared energy analysis rather than hiring specialists. This may be a good idea, but using a camera and accurately interpreting results are two different things. You probably can do it, but your users will need some training, or the exercise may be a complete waste. buildings are operating at optimum ef ciency. Processes change, equipment ages, and buildings are modi ed and can also change in their ef ciency through time. For this reason, organizations today frequently organize internal energy audit teams. For these auditors, digital infrared imaging has become an important tool. Until quite recently, infrared imaging was seen as an activity best out-sourced. For complex projects, or for companies that do not have staff and training, that is still often the case. But an increasing number of companies are taking advantage of lower equipment prices and improved infrared imaging capabilities to buy their own equipment and use their own staff.
Companies Offer Range of Imaging Equipment

Brad Risser from FLIR was a recent presenter at a Technology & Market Assessment Forum sponsored by the Energy Solutions Center. FLIR is one of the global leaders in the manufacture of digital infrared imaging, and offers units ranging from quite basic point-and-shoot models to sophisticated professional units. Risser noted that the interest in digital infrared is increasing because it allows users to identify heat gradients and spot thermal anomalies. He notes, This technology allows us to see heat.
Regular Audits Becoming the Norm

Increasingly, facility owners recognize that energy auditing is not a one-time procedure. It needs to be a continuing routine to assure that manufacturing processes and
Can Quickly Spot Problems

The most basic use of a digital infrared camera with an on-board screen is to allow the user to spot anomalies in a manufacturing or mechanical room such as overheated bearings, belt rubs, failing pipe or tting insulation, hot electrical connections, bad switches, overheated motors, or steam and condensate leaks. The pointand-shoot camera is ideal for these applications. In addition to process applications, the camera can be used to evaluate building energy concerns by identifying uninsulated areas, leaky windows and doors, water damaged areas and other anomalies. A section of exterior wall without adequate insulation will not be detectable by visible light, but this area will show up clearly on the imaging tool as a hot spot. Thus the infrared camera is a useful supplement to other building energy audit resources.
Infrared imaging can be performed by a trained in-house audit team to identify areas of heat loss, failing equipment and steam leaks in an industrial plant. Photo courtesy Fluke.
Camera and Training Vary with Purpose

Gary Orlove is an application engineer with FLIR and is curriculum manager for FLIRs infrared camera training activities. He says that the choice of cameras and the amount of training varies with the inA8 gastechnology / WINTER 12 WWW.ENERGYSOLUTIONSCENTER.ORG
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For Energy Auditing

Fluke Offers Combination Imaging
Building efficiency can be checked. This infrared image shows an area of moisture penetration in roof insulation. Photo courtesy Drysdale & Associates. Fluke is a broad spectrum manufacturer of electronic test tools and also offers a line of digital thermal imaging cameras. An interesting feature available on some of the imaging systems is what is called IR-Fusion technology. This capability allows the user to merge visible light images with infrared images, thereby speeding identification of specific problem areas and simplifying reports on audit results. In addition to general purpose infrared imagers, Fluke offers point-and-shoot imagers designed for process applications as well as units designed specifically for building efficiency analysis. Fluke also emphasizes the importance of training for users of infrared imagers, and offers online basic and in-depth training courses and webinars, as well as training classes conducted by Flukes training partner, The Snell Group. Classes are set for multiple training levels.
tended application. It depends on several factors: How much is the auditors time worth? What type of equipment is being evaluated, what resolution is needed on the equipment surface, and what temperature range is needed? He points out that a foundry would be a very different infrared environment from a meat packing plant. He adds, A qualified auditor can make use of any of the cameras, just like a photographer can use an inexpensive camera, but the results would be better with a better camera. He explains that the same camera equipment can be used for energy auditing on the building and on process equipment. Prices start just below $2,000 and go up.
at customer sites. We offer all three. Beyond the basics on using the camera, the courses include interpretation of the image and procedures for correct temperature measurement. While some energy calculations are taught at the infrared class, the majority of that training is usually included in the auditors general energy auditing learning program.
Images Can Be Stored, Transferred

Orlove points out that all of the cameras have the capability to store the images as desired. The images are initially stored on memory cards in the camera, and then transferred to a PC for archival and report generating purposes. Because the images are in standard file formats, they can be transferred to other sites for analysis or for training purposes.
Include Training in Your Plans

A wide range of thermal imaging products are now available from multiple manufacturers. Whether your interest is doing occasional trouble-shooting or incorporating the imaging equipment into an ongoing audit process, there is equipment made for your needs. Remember the importance of your staff getting startup and continuing training in the use of the equipment. Done the right way, infrared imaging can pay for itself in a very short time. GT
In-Depth Training for Detailed Analysis

Orlove feels that the needed amount of training depends on the depth of analysis the auditor is going to do. Is the auditor just looking for insulation problems, or is it necessary to measure R values and calculate energy losses and savings? For the latter, a minimum of 32 hours of classroom and a couple of weeks of hands-on experience are needed. He points out that FLIR offers these types of training sessions. We do it at our campus, at regional courses we set up, and
www.energySolutionScenter.org
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FLIR www.flir.com/US Fluke www.fluke.com/fluke/usen/products/ categoryti.htm
gastechnology / winter 12
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MICROTURBINES
Power Plus Heat with Reliability, Ef ciency
ITS A GREAT IDEA: Generate your own electric power for use in your plant or on your campus, and use byproduct heat for space heat, water heating, process heat, absorption cooling almost any thermal application. If you have surplus electric capacity, it can be sold back to your utility. Thats the promise with combined heat and power (CHP) installations, and one attractive option is microturbines. These are sometimes called aeroderivative turbines, re ecting their design ancestry as auxiliary power generators for aircraft. But in recent years they have carved out their own improved designs and exible roles.
IN THE NEWS
A leader in the U.S. microturbine industry is Capstone Turbine Corporation, headquartered in Chatsworth. California. Capstone sells microturbine units in the 30, 65 and 200 kW class worldwide, as well as multiple turbine assemblies with capacities in multiples of megawatts. Aaron Tasin from Capstone was recently a presenter at a Technology & Market Assessment Forum sponsored by the Energy Solutions Center.
Green Energy Solution

In his presentation, he emphasized that microturbines are a green energy solution for several reasons. First, they typically burn either natural gas or a waste byproduct gas from a digester, solid waste site or from a petroleum production site. Any of these fuels have smaller carbon footprints than most utility electric generation sources. Secondly, because the microturbine produces both electric power and hot water or steam, it more fully utilizes the fuel energy used. He reminded conference attendees that in large part, because of development of vast reserves of natural gas in shale formations, the U.S. now has a 100+ year supply of natural gas in the ground, plus a large potential for methane production from reclaimed land ll gas, and from agricultural and municipal wastewater digesters. He indicated that world reserves of natural gas are three times those of petroleum.
Growing in Size and Flexibility

Todays North American commercial microturbine products were initially introduced in the 30 kilowatt (kW) size class. They have since been supersized to 60, and today 200 or 250 kW scale. One U.S. manufacturer also offer multiple turbine packages with coordinated controls and enclosures so they operate as a unit rated at up to 1,000 kW (1 MW). Beyond this, multiple packages can be combined for total capacities of 5 MW and more. Byproduct heat is extracted from the turbine exhaust at temperatures of 600 F or higher. Because all of the waste heat is present in the exhaust gas stream, it is relatively simple to direct this waste heat through a steam generator to make steam to support or supplement various comfort and process applications. A microturbine can provide hot air, steam, or hot water for various industrial applications, or can also supply thermal energy to absorption chillers for building or process cooling.
Ef ciency To 85%
Tasin suggested that a microturbine installation that fully uses the thermal byproduct has a total ef ciency of 85% compared to 58% or less for systems that use utility electric power plus an on-site boiler. Further, he emphasized that natural gas as a fuel has much lower emissions than the typical utility mix of coal, oil and some nuclear generation. Combine the lower initial emissions with the lower total energy input, and there can be no argument that this is truly a green solution. Tasin noted that with thousands of turbines installed in locations around the world serving many types of heat and electric loads, microturbine technology is in the mainstream and an attractive solution for many types of users. He indicated that typically owners size their installation to meet their thermal requirement, and use all or as much of the electric output as possible and if there is a surplus, sell it to their interconnected central-station electric utility. In this way, they get the full bene t of both the thermal and electric output.
Cutaway view of microturbine sections. Illustration courtesy FlexEnergy.
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Three 250 kW gas turbines provide both electric power and water heating at the John Muir Medical Center in Walnut Grove, California. Photo courtesy FlexEnergy.
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Serving Critical Winery Load

An example of an industrial load served with Capstone microturbines is Vineyard 29 in the Napa Valley of California. Here two 60 kW machines provide power to the plant for daily operations, plus heat for building heating in the colder months and to supply an absorption chiller for cooling in the hot months. The units run parallel with utility electric service, but can pick up load in the event of an outage during the critical grape harvesting period. FlexEnergy manufactures microturbines for use in industrial, institutional and commercial settings. This company acquired Ingersoll Rand Energy Systems in 2010 and is headquartered in Irvine, California, with a worldwide spare parts depot at that location. Gas turbine production and assembly is done at its plant in Portsmouth, New Hampshire.
ers want to take full advantage of the thermal output of the machine. Generally we recommend that the unit be sized for the expected thermal load. She points out that FlexEnergy turbines meets all current and upcoming emission standards, and the Flex Turbine MT250 was the rst combustion technology ever to meet the California Air Resource Board (CARB) 2007 emission standards. No exhaust catalyst treatment is required, and the NOx output is less than 5 ppm. The product has integral heat recovery and can be used for a wide variety of industrial applications that require hot air, hot water, steam or chilled water.
CAPSTONE TURBINE CORPORATION www.capstoneturbine.com DOE INFORMATION ON MICROTURBINES www1.eere.energy.gov/manufacturing/ distributedenergy/microturbines.html ENERGY SOLUTIONS CENTER INFORMATION ON MICROTURBINES www.energysolutionscenter.org/gas_solutions/ microturbines.aspx FLEXENERGY www. exenergy.com
generates 3.3 million Btu per hour of thermal energy for water heating and meets rigorous CARB emission requirements. The medical centers goal was a system with high reliability and minimal maintenance.
Medical Center Reduces Demand Charges

An example of an institutional user of microturbines is a recent addition to the John Muir Medical Center in Walnut Grove, California. This 324-bed acute care facility chose three Flex Turbine MT250 units, for an installed capacity of 750 kW. The goal of the project was to reduce utility electric demand charges, increase power supply reliability, and provide an economical source of domestic hot water for facility demands. The 2011 installation
Is it Right for You?

Is there a gas turbine in your future? If you have natural gas service and a need for both electric power and thermal energy, it might well be the best solution. Your engineer should be able to help you calculate the potential costs and savings. Small gas turbines are in the mainstream, and can be a great solution for reducing costs and using fuel resources more ef ciently, while reducing emissions and lowering your contribution to greenhouse gases. Give it some thought. GT
gastechnology / WINTER 12 A11
Wide Range of Applications

According to company spokesperson Su Anne Huang, the current product is the Flex Turbine MT250, a 250 kW-rated unit with broad applications for industrial and institutional users. Huang notes, In most of the installations weve done, ownWWW.ENERGYSOLUTIONSCENTER.ORG
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Maintaining Ef ciency Is a Continuing Goal

TOO OFTEN A HIGH-EFFICIENCY package boiler is purchased at a premium price and then allowed to decline in performance from lack of proper maintenance or from incorrect operation. Todays boilers are rugged and nely-tuned machines. Digital burner controls and on-board ue gas analysis make the job easier, but its as important as ever to keep an eye on the goal of optimum ef ciency.
Run Your Boiler at Its Best
CLEAVER-BROOKS www.cleaver-brooks.com DOE ON BOILER EFFICIENCY www1.eere.energy.gov/manufacturing/tech HURST BOILER & WELDING CO. www.hurstboiler.com MIURA BOILER www.miuraboiler.com
Feedwater is Critical
Perhaps the single most important item to watch is feedwater quality. Good feedwater is critical for the life and ef cient operation of a boiler. Rakesh Zala, Director of Product Engineering for Cleaver-Brooks Packaged Boiler Systems, points out that poor feedwater quality can lead to premature boiler failure. It can also lead to fouling and scale buildup on heat transfer surfaces, raising stack temperature and reducing ef ciency. It is important to follow manufacturers recommendations for feedwater pH and to use the recommended anti-scaling treatments. A modest investment in feedwater treatment chemicals and periodic tube cleaning can pay large rewards in boiler integrity and ef ciency. Follow the recommended blowdown frequency, and inspect the boiler interior regularly for signs of erosion or scaling.
In many industrial plants, the boiler system is the single largest energy user. It makes sense to regularly check its operating efficiency, and run boilers near their most efficient points. Photo courtesy Cleaver-Brooks.
Find the Sweet Spot and Stay There

Most steam boilers have ef ciency sweet spots when ring somewhere between 60% and 80% of maximum capacity. Condensing hot water boilers are most ef cient at rates somewhat below this. If you have a single boiler, you may not have a choice of the ring rate, but if you have multiple boilers, you should be trying to operate as many as possible at or near the sweet spot. Ask your system designer or the boiler manufacturer for information on what ring rates offer the highest ef ciency. Related to the discussion of sweet spots is the reality that for many industrial and institutional systems, there is a year-round need for steam. Yet summer steam requirements are much less, so a boiler has to operate far from its optimum rate, or cycle an unacceptable number of times a day. This hurts year-round ef ciency.
Keep Controls in Calibration

Zala also points out that newer boiler controls often use an O2 sensor to optimize combustion. This means many fewer adjustments of draft and fuel linkages are needed than with older mechanical controls. However, he says, Typically the sensor requires periodic calibration. Some control systems are designed to perform automatic calibration. Check with the control system provider to con rm the status of your system. Chad Fletcher from Hurst Boiler emphasizes the importance of regular maintenance and echoes comments of others on the importance of maintaining feedwater quality. He points out, The newer technology digital controls do offer easier maintenance and offer easier setup and dealing with problems. He notes that much of this maintenance work can be done during the bi-annual boiler inspection. Flue gas analysis will give information on boiler ef ciency. Typically you want excess air less than 15% and no measurable carbon monoxide (CO). This will indicate clean combustion. Higher excess air or the presence of CO indicates adjustments are needed. If your boiler offers on-board ue gas analysis, then be sure to take advantage of this very useful tool.
A12 gastechnology / WINTER 12
A Place for Ponies

The solution may be a small pony boiler for off-season minimum loads. Small horizontal or vertical tube or tubeless boilers are available to match up with your off-peak pressure and volume requirements. Adding a pony boiler can make your entire plant more ef cient year-round. According to the DOE, boilers are commonly the single largest energy using device in many plants and institutions. Doesnt it make sense to closely watch the ef ciency of this system and try for the best? GT
11/23/2012 3:38:42 PM
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40 Under 40 program awardees will:
Be highlighted in major media arenas as a Consulting-Specifying Engineer 40 Under 40 winner Be offered networking opportunities with other 40 Under 40 awardees, enlarging their professional circle Increase the exposure of the company by highlighting projects the young engineer has worked on Improve the companys recruitment efforts by showcasing young employees Receive a handsome plaque to show off their accolades
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Product & Literature Digest
Cat Updates Generator Set Ratings Guide

Cat has updated its electric power ratings guide for generator sets with new information on the latest gas and diesel powered models, in addition to rental units. Full definitions of all ratings are included, as well as detailed overviews of accompanying system products including switchgears, UPS and ATS. Conversion tables cover electrical, connecting and starting systems and ventilation and temperature requirements. An overview of product support plans provides a comprehensive electric power system package. Visit www.catelectricpowerinfo.com/pr
Genset paralleling
The ability to operate generator sets in parallel with each other or with the utility can add function, flexibility and economy to many standby power applications. MTU Onsite Energy generator sets are equipped with advanced digital microprocessors that facilitate peer-to-peer generator set paralleling and generator-set-to-utility paralleling without the expense or space requirements of traditional paralleling switchgear. www.mtuonsiteenergy.com.
Why Should You Filter Your Water?
Scale formation reduces the heat transfer rate and increases the water pressure drop through the heat exchanger and pipes. In fact, one study has shown that .002" fouling will increase pumping needs by 20%.
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Advertiser Index
Request more information about products and advertisers in this issue by using the http://csemag.com/information link and reader service number located near each item. If youre reading the digital edition, the link will be live. You may also check the circle adjacent the page reference to indicate which companies you are interested in, then FAX this back to CSE at 630-214-4504 for FREE information. When you contact a company directly, please let them know you read about them in Consulting-Specifying Engineer.
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PUBLICATION SERVICES
Jim Langhenry, Co-Founder and Publisher, CFE Media 630-571-4070, x2203; Jlanghenry@CFEMedia.com Steve Rourke, Co-Founder, CFE Media 630-571-4070, x2204, SRourke@CFEMedia.com Trudy Kelly, Executive Assistant 630-571-4070, x2205, TKelly@CFEMedia.com Elena Moeller-Younger, Marketing Manager 630-571-4070, x2215; EMYounger@CFEMedia.com Michael Smith, Creative Director 630-779-8910, MSmith@CFEMedia.com Paul Brouch, Web Production Manager 630-571-4070, x2208, PBrouch@CFEMedia.com Michael Rotz, Print Production Manager 717-766-0211 x4207, Fax: 717-506-7238 mike.rotz@frycomm.com Karie Burt, Account Director, U.S. Sales 212-584-9374; kburt@mardevdm2.com Rick Ellis, Audience Management Director Phone: 303-246-1250; REllis@CFEMedia.com letters to the editor Please e-mail us your opinions to ARozgus@CFEMedia.com or fax us at 630-214-4504. Letters should include name, company, and address, and may be edited for space and clarity. Information For a Media Kit or Editorial Calendar, email Trudy Kelly at: TKelly@CFEMedia.com.
Baldor Electric Company ................ C-2...................1 .............479-646-4711 ......... www.baldor.com .............................................. CFE Media LLC ................................. 47 ....................................630-571-4070 ......... www.cfemedia.com.......................................... ClimaCool Corporation................... 48 ....................20 ...........405-745-3185 ......... www.climacoolcorp.com.................................. CSE 40 Under 40 ............................. 61 ....................................630-571-4070 ......... www.csemag.com/40under40......................... Danfoss ............................................ 15 ....................9 .............410-931-8250 ......... www.inverterscroll.danfoss.com .................... Emerson Network Power............... 33 ....................16 ...........614-841-7025 ......... www.EmersonNetworkPower.com/CoolEf ciency Enercon Engineering, Inc. .............. 11 ....................6 .............800-218-8831 ......... www.enercon-eng.com.................................... Fike Corp.......................................... 13 ....................7 .............866-758-6004 ......... www. ke.com................................................... Generac Industrial Power .............. 1 ......................2 .............800-436-3722 ......... www.generac.com............................................ Greenheck Fan Corp ....................... 41 ....................18 ...........715-359-6171 ......... www.greenheck.com ....................................... Hochiki America Corp..................... 18 ....................11 ...........714-522-2246 ......... www.hochiki.com ............................................. International Exposition Co........... 48 ....................23 ...........203-221-9232 ......... www.ahrexpo.com ........................................... Keltech, Inc ...................................... 27 ....................14 ...........800-999-4320 ......... www.keltech-inc.com .......................................
REPRINTS
For custom reprints or electronic usage, contact: Wrights Media Nick Iademarco Phone: 877-652-5295 ext. 102 Email: niademarco@wrightsmedia.com
Lutron Electronics Co...................... C-4...................22 ...........888-588-7671 ......... www.lutron.com............................................... Mee Industries, Inc ......................... 46 ....................19 ...........626-359-4550 ......... www.meefog.com ............................................ Reliable Controls............................. 16 ....................10 ...........250-475-2036 ......... www.reliablecontrols.com/contact ................. Schneider Electric............................ 6, 21 ................5, 12 .......847-397-2600 ......... www.schneider-electric.com............................
PUBLICATION SALES
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Schweitzer Engineering Labs ........ 14 ....................8 .............509-336-7946 ......... www.selinc.com................................................ Siemens Building Technologies ..... 5 ......................4 .............847-215-1050 ......... www.usa.siemens.com .................................... SimplexGrinnell ............................. 35 ....................17 ...........800-746-7539 ......... www.simplexgrinnell.com ............................... Solutions for Engineers.................. 37 ....................................630-571-4070 ......... www.csemag.com ............................................ Thomas & Betts Corporation ......... 29 ....................15 ...........901-252-8000 ......... www.tnb.com ................................................... Trane ............................................... Bellyband, 24 .13 ...........651-407-4189 ......... www.trane.com ................................................ Wheatland Tube JMC Steel Group 2 ......................3 .............800-257-8182 ......... www.wheatland.com....................................... Yaskawa America, Inc .................... C-3...................21 ...........800-927-5292 ......... www.yaskawa.com ..........................................
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2 More Minutes
Meeting the challenges of globalization
This firms globalization process has come with many lessons learned.
ack in 1969 when Rolf Jensen founded his fire protection engineering firm, Rolf Jensen & Associates, the center of the universe was Chicago, our headquarters city. In the beginning, our clients were Chicago-based architecture and engineering (A&E) firms that needed RJAs expertise in code consulting in order to achieve their innovative building designs while meeting the intent of the life safety codes and standards. Today, our company has offices providing a wide range of services around the world and has participated in projects in more than 60 countries. I can assure you that our firms globalization process has come with many lessons learned.
rience makes them better, more confident professionals. It also provides them with an opportunity to take some extra time to enjoy the wonderful sights and people in all parts of the world.
Stick to your project management standards
Every client expects a quality solution to a specific challenge. In the engineering consulting profession, as in just about every other type of business, we provide consistent quality performance by adhering to best practice project management standards. Just because the BY MARTIN (MICKEY) REISS, project happens to be located in Abu PE,FSFPE Dhabi or Macau doesnt change the need THE RJA GROUP INC. to follow proven procedures. You will need to adapt to local requirements, but the basic attention Support your clients globally to quality standards should never vary. As we pursued project opportunities, first in the United States and then globally, our primary goal was to deliver our scope of services wherever our clients worked in Apply the latest proven technology the world. For example, as the market in China started Notice I didnt say to be on the bleeding edge of techto emerge, we opened an office in Shanghai and started nology. Thats a recipe for disaster. But global projects building a relationship with the Chinese fire officials. do tend to test the limitations of communications. So you When our clients began arriving to do work in China, we need to make sure your technology gurus evaluate each were already established there and were able to provide global opportunity. Technological tools can range from them with a combination of local knowledge and technitablets and project management apps to cell phones and cal expertise. Weve repeated this strategy as we opened file transfer protocol (FTP) sites. Just keep in mind, one offices in other global locations. reason youre being chosen to participate in the project undoubtedly is the reputation U.S. firms have for being on the leading edge. Deploy your technical resources as a team In engineering consulting firms, the most important resources are our technical staff. In todays world, our The results can be incredible professionals are smart, curious, aggressive, and always In the future when I retire from RJA, I hope that one of looking for a team challenge. Global projects provide the my legacies at our company will be the pursuit of a global opportunity to marshal resources from throughout the presence. It started when I joined the company in the early company and focus these strengths on a project in Asia, 1990s, and I cant tell you how gratifying it is to talk with the Middle East, or anywhere in the world where our cliour consultants who have participated in landmark projects ents are operating. all over the world. Going global is not an easy journey, but Whether this calls for rotating people in and out of the it is a destination definitely worth the trip. project site, or relocating them for a specific period of time, weve found that global assignments are highly sought after Martin (Mickey) Reiss is president and CEO of The RJA by our best people. They appreciate the opportunity to work Group Inc., parent company of Rolf Jensen & Associates together on a challenging project with a variety of teamInc. He is a member of the Consulting-Specifying Engimates in a new setting. What they take away from the expeneer editorial advisory board.
www.csemag.com
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WHAT YOU ALWAYS WANTED
Our customers tell us that quality means no product hardware failures. Now, thats a gift that keeps on giving. When you take Yaskawa drives out of the box, you can count on them to work. In fact, Yaskawa products have a meantime-between-failure rate (MTBF) of up to 28 years. That means your engineers can spec Yaskawa and never have to worry. Just program, plug and play. Get what you want, every time. Call Yaskawa.
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Lutron systems help the Empire State Building achieve sustainability goals.
Lutron lighting controls and sensors save up to 65% of lighting energy.*

Wireless simplies installation and minimizes disruption Flexible for easy retrots or new construction Expandable add to a system or recongure at any time
Lutron products are state-of-the-art, cost effective, and architecturally beautiful. We worked with Lutron to develop wireless solutions for the Empire State Building now you can buy our choice for energy-saving light control.
Anthony Malkin Empire State Building Company
Empire State Building sustainability goals

Building energy reduction Building carbon emission reduction (over the next 15 years) Annual building energy bill reduction Lutron contributions toward overall goals Projected lighting energy reduction
CSE - DEC 2012 - DOMUS, INC. - 215-782-2800
38% 105,000 metric tons $4.4 mil
65%
Projected lighting controls installed payback 2.75 years** For more information please visit www.lutron.com/esb or call 1.800.523.9466 for 24/7 support.
* Compared with manual (non-automated) controls, up to 65% lighting energy savings is possible on projects that utilize all of the lighting control strategies used by Lutron in the ESB project (occupancy sensing, high-end trim, and daylight harvesting). Actual energy savings may vary, depending on prior occupant usage, among other factors.
** Estimates based on Lutron controls installed in ESB pre-built tenant space. Payback claims assume 65% reduction in energy costs and energy rates of 22 cents per kWh. Actual payback terms may vary. The Empire State Building design is a registered trademark and used with permission by ESBC. Empire State Building sustainability goals are provided by ESBC and contain energy-saving strategies in addition to lighting control.
Learn about our other energy-saving projects at www.honestbuildings.com/lutron
2012 Lutron Electronics Co., Inc. | P/N 368-2856 REV B input #22 at www.csemag.com/information
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The Industrial Choice

2011 Baldor Electric Company

How do you define redundancy?

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CONTENT SPECIALISTS/EDITORIAL CONTENT SPECIALISTS/EDITORIAL AMARA ROZGUS, Editor in Chief/Content Manager

Amara Rozgus Editor in Chief

Looking backwardand ahead

EDITORIAL ADVISORY BOARD EDITORIAL ADVISORY BOARD

PAUL BEARN, PE, PAUL BEARN, PE,

TIMOTHY E. KUHLMAN, PE, RCDD, TIMOTHY E. KUHLMAN, PE, RCDD,

ERIN MCCONAHEY, PE, ERIN MCCONAHEY, PE,

SYED PEERAN, PE, Ph.D., SYED PEERAN, PE, Ph.D.,

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