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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. CONSULTING-SPECIFYING 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: [email protected]. 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: [email protected]. 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.

COVER STORY

22 | How to select an air handling unitAir handling units come in all shapes and sizes. Learn to balance and prioritize all of the choices related to perfor-mance, efficiency, maintainability, and space constraints.BY ROB MCATEE, PE, AND EVAN RILEY, PE, CEM, LEED BD+C

DEPARTMENTS

07 | ViewpointLooking backward—and ahead

08 | MEP RoundtableCollege campus engineering

17 | Career SmartUse personality typingto increase profits

19 | Codes & StandardsConnecting buildingsto the Smart Grid

48 | New Products

63 | Advertiser Index

64 | 2 More MinutesMeeting the challengesof globalization

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30 | How to specify an indoor lighting systemBy following a few guidelines, engineers and lighting designers can specify an appropriate light-ing system for a facility.BY MIKE LARSEN, LEED AP

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38 | Wireless building controlsCreative use and selection of wireless devices can potentially reduce construc-tion costs, decrease construction time, and add future flexibility to buildings.BY MICHAEL A. CULVER, PE

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3www.csemag.com Consulting-Specifying Engineer • DECEMBER 2012

DECEMBER 2012

ON THE COVER: This building information model (BIM) rendering shows a multi-story office building’s 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 coordina-tion. Autodesk’s Revit and Navisworks programs were used to render this. Courtesy: H&A Architects and Engineers

CSE1212_TOC_V6msFINAL.indd 3 12/5/12 11:30 AM

Consulting-Specifying Engineer • DECEMBER 2012

Winter 2012 Pure PowerRead about electric vehicle charging sta-tions 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.

Consulting-Specifying Engineer is now on Facebook, Google+, LinkedIn, and Twitter. Follow CSE, join the discus-sions, and receive news and advice from your peers.

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

630-571-4070, x2211, [email protected]

AMANDA MCLEMAN, Project Manager630-571-4070 x2209, [email protected]

BOB VAVRA, Content Manager 630-571-4070, x2212, [email protected]

MARK HOSKE, Content Manager 630-571-4070, x2214, [email protected]

PETER WELANDER, Content Manager 630-571-4070, x2213, [email protected]

MICHAEL SMITH, Creative Director 630-779-8910, [email protected]

CHRIS VAVRA, Content Specialist630-571-4070, x2219, [email protected]

BRITTANY MERCHUT, Content Specialist630-571-4070, x2220, [email protected]

EDITORIAL ADVISORY BOARDANIL AHUJA, PE, LEED AP, RCDD, President, CCJM Engineers, Chicago

PATRICK BANSE, PE, LEED AP, Senior Mechanical Engineer,

Smith Seckman Reid Inc., Houston

PAUL BEARN, PE, Associate Electrical Services Engineer,

KlingStubbins, Philadelphia

MICHAEL CHOW, PE, LEED AP BD+C,Principal, Metro CD Engineering LLC, Dublin, Ohio

DOUGLAS EVANS, PE, FSFPE, Fire Protection Engineer, Clark County Building Division, Las Vegas

RAYMOND GRILL, PE, FSFPE, Principal, Arup, Washington, D.C.

RAJ P. GUPTA, PE, LEED AP, President, Environmental Systems Design Inc., Chicago

GERSIL KAY, President, Conservation Lighting Intl. and Building Conservation

Intl., Philadelphia

WILLIAM KOSIK, PE, LEED AP, Managing Principal, EYP Mission Critical

Facilities Inc., Chicago

TIMOTHY E. KUHLMAN, PE, RCDD, Electrical Engineer CH2M Hill, Portland, Ore.

KEITH LANE, PE, RCDD, LC, LEED AP, President, Lane Coburn & Assocs., Seattle

KENNETH L. LOVORN, PE, President, Lovorn Engineering Assocs., Pittsburgh

ALI MAHMOOD, PE,Senior Mechanical Engineer, Stanley

Consultants Inc., Chicago

ERIN MCCONAHEY, PE, Associate Principal, Arup, Los Angeles

SYED PEERAN, PE, Ph.D., Senior Engineer, Camp Dresser & McKee Inc.,

Cambridge, Mass.

MARTIN H. REISS, PE, FSFPE, President, CEO, The RJA Group Inc., Framingham, Mass.

BRIAN A. RENER, PE, LEED AP, Electrical Platform Leader and Quality Assurance Manager,

M+W Group., Chicago

DAVID SELLERS, PE, Senior Engineer, Facility Dynamics Engineering Inc., Portland, Ore.

GERALD VERSLUYS, PE, LEED AP, Principal, Senior Electrical Engineer, TLC Engineering

for Architecture, Jacksonville, Fla.

MIKE WALTERS, PE, LEED AP,Principal, Confluenc, Madison, Wis.

PETER D. ZAK, PE, Principal, GRAEF, Milwaukee

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

630-571-4070, x2211, [email protected]

AMANDA MCLEMAN, Project Manager630-571-4070 x2209, [email protected]

BEN TAYLOR, Project Manager 630-571-4070, x2219, [email protected]

BOB VAVRA, Content Manager 630-571-4070, x2212, [email protected]

MARK HOSKE, Content Manager 630-571-4070, x2214, [email protected]

PETER WELANDER, Content Manager 630-571-4070, x2213, [email protected]

MICHAEL SMITH, Creative Director 630-779-8910, [email protected]

CHRIS VAVRA, Content [email protected]

BRITTANY MERCHUT, Content Specialist630-571-4070, x2220, [email protected]

EDITORIAL ADVISORY BOARDANIL AHUJA, PE, LEED AP, RCDD, President, CCJM Engineers, Chicago

PATRICK BANSE, PE, LEED AP, Senior Mechanical Engineer,

Smith Seckman Reid Inc., Houston

PAUL BEARN, PE, Associate Electrical Services Engineer,

KlingStubbins, Philadelphia

MICHAEL CHOW, PE, LEED AP BD+C,Principal, Metro CD Engineering LLC, Dublin, Ohio

DOUGLAS EVANS, PE, FSFPE, Fire Protection Engineer, Clark County Building Division, Las Vegas

RAYMOND GRILL, PE, FSFPE, Principal, Arup, Washington, D.C.

RAJ P. GUPTA, PE, LEED AP, President, Environmental Systems Design Inc., Chicago

GERSIL KAY, President, Conservation Lighting Intl. and Building Conservation

Intl., Philadelphia

WILLIAM KOSIK, PE, LEED AP, Managing Principal, EYP Mission Critical

Facilities Inc., Chicago

TIMOTHY E. KUHLMAN, PE, RCDD, Electrical Engineer CH2M Hill, Portland, Ore.

KEITH LANE, PE, RCDD, LC, LEED AP, President, Lane Coburn & Assocs., Seattle

KENNETH L. LOVORN, PE, President, Lovorn Engineering Assocs., Pittsburgh

ALI MAHMOOD, PE,Senior Mechanical Engineer, Stanley

Consultants Inc., Chicago

ERIN MCCONAHEY, PE, Associate Principal, Arup, Los Angeles

SYED PEERAN, PE, Ph.D., Senior Engineer, Camp Dresser & McKee Inc.,

Cambridge, Mass.

MARTIN H. REISS, PE, FSFPE, President, CEO, The RJA Group Inc., Framingham, Mass.

BRIAN A. RENER, PE, LEED AP, Electrical Platform Leader and Quality Assurance Manager,

M+W Group., Chicago

DAVID SELLERS, PE, Senior Engineer, Facility Dynamics Engineering Inc., Portland, Ore.

GERALD VERSLUYS, PE, LEED AP, Principal, Senior Electrical Engineer, TLC Engineering

for Architecture, Jacksonville, Fla.

MIKE WALTERS, PE, LEED AP,Principal, Confluenc, Madison, Wis.

PETER D. ZAK, PE, Principal, GRAEF, Milwaukee

Editor’s Viewpoint

Send your questions and comments to:[email protected]

Looking backward—and ahead

All sentimentality aside, December is the perfect time to review where we’ve been

so we know where we’re going. Here’s a look at 2012—with 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 newgoals.

March: This month’s 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: CSE’s annual Product of the Year awards—which opens Jan. 2, 2013—highlight 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. Nomi-nate 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 stud-ies by sending them to [email protected].

July: In July, my editorial discussed high-performance buildings, and the technologies and systems associated

with them. This is obviously a recur-ring 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 infor-mation, visit www.csemag.com/giants.

September: Each quarter, the Pure Power supplement focuses on all things power: generators, selective coordination, arc flash, etc. Electri-cal systems continue to be crucial to a building’s success, and renewable energy and electrical efficiency are creeping into the pages of this supple-ment.

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 you’ve always dreamed of.

Amara Rozgus Editor in Chief

1111 W. 22nd St. Suite 250, Oak Brook, IL 60523630-571-4070 Fax 630-214-45041111 W. 22nd St. Suite 250, Oak Brook, IL 60523


CSE1212_VIEW_V5msFINAL.indd 7 12/5/12 11:31 AM

8 Consulting-Specifying Engineer • DECEMBER 2012 www.csemag.com

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 today’s economic climate. Build-ings are now almost always designed with the intention of being 50- to 100-year build-ings and the energy efficiency of mechanical, electrical, plumbing (MEP), and fire protec-tion systems is a priority. In many types of buildings, those systems are designed with significant flexibility to accommodate multi-ple 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 educa-tion facilities that we deal with have aging central plants and infrastructure with mini-mal 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 operat-ing. 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-

lege campuses must understand the unique challenges their structures pose, the most sig-nificant 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 trans-formers, water services, etc. The intercon-nection 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 isn’t good as-built documenta-tion for the interconnections, so extensive field investigation is required.

CSE: How have the needs and charac-teristics of colleges changed in recent years?

Lembo: The American College & Univer-sity Presidents’ Climate Commitment has driven many of the higher education facili-ties 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 model-ing has allowed our firm to analyze energy consumption early on and present this infor-mation to allow the owner and architect to make key decisions early on.

Maniktala: In recent years, colleges and

MEP Roundtable

PARTICIPANTS

Michael BrogePrincipal

Affiliated Engineers Inc.Madison, Wis.

Joseph Lembo, PEPartner

Kohler Ronan Consulting Engineers

Danbury, Conn.

Rick Maniktala, PE, LEED AP, CxA, DBIA, HFDP

Principal/Vice PresidentM.E. Group

Overland Park, Kansas

Joseph Lembo, PE

Rick Maniktala, PE, LEED AP,

College campus engineeringColleges and universities bear the important responsibility of mold-ing 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.

CSE1212_MEP_Roundtable_V5msFINAL.indd 8 12/5/12 11:32 AM


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, innova-tive advanced degree programs are in demand and have been created while campuses race to offer these to stu-dents. 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 rela-tive to systems, regulations, and proj-ect delivery. As the sustainable design movement has matured, many institu-tions have moved from self-certifica-tion of U.S. Green Building Council LEED-designed project to formal LEED application and certification. State governments have developed—or are developing—energy efficiency standards for public buildings that sig-nificantly exceed state energy codes. The emphasis on sustainability and

energy efficiency often further com-plicates already complex building sys-tems and controls, and many institu-tions 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 institu-tion administrators are choosing to expand and remodel existing facilities rather than construct new buildings. What unique challenges do retrofitted buildings present that you don’t encounter on new structures?

Maniktala: Existing buildings on col-lege campuses often have infrastructure services that are inefficient when com-pared to today’s standards. For exam-ple, 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 wheth-er the infrastructure upgrade could be afforded, the university elected to include an alternate design with total replacement of all the dual-duct air han-dling 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 tie-in, electrical service, etc. This example is not unique; many existing buildings on campuses across the country would benefit immediately from similar infra-structure upgrade/modernization proj-ects to reduce energy consumption and improve thermal comfort and indoor air quality.

Broge: Older buildings’ structural elements—that is, columns, beams, and

College campus engineering

The team at Kohler Ronan Consulting Engineers worked with architect Robert Stern on Marist College’s 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



MEP Roundtable

floor-to-floor heights—are 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 obso-lescence. Existing facades generally

require upgrades with increased insu-lation, 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 renova-tions will require phased renovations, relocating a sequence of smaller user groups. And phased renovation requires management of disruptions and incon-veniences 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 energy-efficient. Developing a plan of pas-sive “envelope” and active “mechani-cal” approaches to not only improve energy efficiency but also incorporate sustainable design elements is impor-tant. This is where the collaborative design effort is required from all design team members.

CSE: What renewable energy systems have you specified on a college campus, and what were the results?

Broge: Colleges and universities

are more likely to invest in certain renewable energy technologies than many client types. Systems using geo-thermal, solar hot water heating, and photovoltaic (PV) power generation technologies have become increas-ingly common in our project work. The effectiveness—and, thus, advis-ability—of these applied renewable

technologies is largely dependent upon the geographic and climatic location of the project and the purpose for incor-poration of the technology itself. For example, we designed a geothermal system as part of a building renova-tion at a larger public Midwestern university for the purpose of provid-ing 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 environ-mental cooling, but also providing nearly all of the building’s year-round heating and cooling energy. A less successful geothermal appli-cation was designed for a research building at another large public Mid-western university that requested the system for demonstration purposes. The complexity of this system has cre-ated challenges to balance the system’s 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 watt—about $10/W a few years ago, though we have designed several “dem-onstration” projects corresponding to that number. Current installed PV costs are nearer $5/W due to improvements to the technology and greater familiar-ity with its installation. New building codes pertaining to PV are just coming

into effect, and may impact installed cost.

Lembo: We have found institu-tional clients more receptive to inno-vative design strategies since many judge project merit based on intrinsic educational value and environmen-tal impact rather than pure econom-ics. Past successes for these clients include ground-source heat pumps (GSHPs) supplemented by solar evac-uated 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 ben-efits 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 instal-lations benefit from grid parallel net metering. However, many utility pro-viders preclude college campuses with distributed energy systems from par-ticipating in net metering contracts. Without the ability to use the grid as a battery, designing practical and finan-cially justifiable on-site generation requires synchronizing energy produc-tion 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 loads—all while reducing installed chiller size. Recently our firm conduct-ed 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 addi-tional 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.

“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


With over 37,000 projects in 110 countries around the world,Enercon Engineering has established itself as a leader in thepower generation industry. We continue to meet our customersexact specifications and requirements, however unique, with afull lineup of power generation products. Enercon is committedto engineering excellence, producing the highest quality productin every custom designed project we build.

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7753 CS&E 213_I:213_I 11/12/12 2:38 PM Page 1




MEP Roundtable

Maniktala: The Student Learning and Engagement Building at the Community College of Denver (CCD) will consoli-date most of CCD’s 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 student’s connection with the outdoors. These include natural ventilation strategies,

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 ven-tilation 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 opti-mized through energy modeling, we anticipate that this project will use only 50% of the energy required for the baseline building. The project is target-ing LEED Gold.

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-tory building constructed 30 years ago with air conditioning for each residen-tial 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

always the question. One successful method is to implement window sen-sors interlocked with the air condition-ing 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

gradually over a period of time, allow-ing both the designers and owners to become versed with most code changes and their design impacts. Sustainabil-ity 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 cer-tain high-energy-consuming build-ing types, has created challenges. We are currently involved in the design of a larger institutional physical sci-ences 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 building’s energy consumption. The state requires the building, includ-ing its processes, to be 30% more ener-gy efficient than the energy code allows. With a fixed budget, and with limita-tions on the use of renewable energy sources, it became impossible to meet the requirement without significant diversion of the project’s program fund-ing—a 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

the large amount of servers planned for the data center.

CSE: How do such codes/stan-dards vary from region to region?

Lembo: We are noticing that many states have their own specific mandates. We recently complet-ed a performing arts center design at New Mexico State University. The project needed to meet a governor’s 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-fund-ed 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 remov-ing their “state-isms” from their own unique code requirements—and are becoming more accepting of the inter-national code requirements as they are written. There continue to be excep-tions, but standardization of codes and standards will obviously help the design community with both design improvement and code compliance.

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 sys-tems within new construction or, more importantly, retrofitting existing build-ings. Many other jurisdictions in which

“State and local code authorities are gradually removing their

‘state-isms’ from their own unique code requirements—and are

becoming more accepting of international code requirements

as they are written.” — Michael Broge


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universities reside have instituted localordinances, 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 ulti-mate goal; fire sprinklers are only one major facet. Students as well as parents have increased their expected levels of protection. Installing fire sprinklers ulti-mately and indirectly creates a higher level learning environment.

CSE: What unique requirementsdo HVAC systems in colleges have?

Broge: Our firm primarily designstechnically complex science and tech-nology buildings for our college and university clients. By their nature, these buildings consume large quantities of

energy, generally with HVAC systemsleading the consumption. Our institu-tional 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 equip-ment. We will often use larger fans and pumps so we can reduce the number of them.

Lembo: Properly sizing of HVACsystems 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 fansand ventilation equipment to enhance indoor air quality (IAQ) in a recent college project.

Lembo: In designing two recent dor-mitories 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 build-ings our firm normally designs, IAQ is addressed through a vari-ety of technologies and strategies. 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). This flushes contaminants and odors from laboratories where a return air system would simply spread con-taminants to other spaces. We use air movement and space pressurization strategies to contain and remove space

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contaminants by cascading ventilationair from cleaner spaces to dirtier spaces, such as from a corridor to a laboratory. Use of higher ventilation air filtration efficiencies—perhaps 90% efficient filters—is also commonly used today.

When we design larger classrooms and lecture spaces, we try to use such dis-tribution strategies as vertical displace-ment 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.

CSE: Describe a recent boiler or chiller plant college campus project.

Broge: Our firm is currently in finaldesign of a larger project that will

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 sys-tem 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 con-nect to existing campus infrastructure. Controls will comply with the North American Electric Reliability Corp. (NERC) standards due to the existing power generation complex.

MEP Roundtable

Read the longer version of this online at: www.csemag.com/archives.

“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

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Given that labor is typically a mechanical, electrical, plumbing (MEP), and fire protection engi-

neering firm’s 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 cul-tural transformation increases productiv-ity, 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. Here’s how:

Hiring: The candidate assessment and selection process in MEP firms can be inconsistent, subjective, and ineffi-cient. And hiring the wrong person for a position, or someone who doesn’t fit well into your firm’s 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 valu-able 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 resolu-tion: 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 motivators—and a lot of time and energy gets wasted on misat-tributing behaviors and attitudes. Typ-ing 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 com-parison to the requirements of a par-ticular 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, princi-pals, etc.) could show how compatible or incompatible the personalities/cul-tures 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 over-all 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 accom-modate for differences in communica-tion styles, preferences, and motivations, and more rapidly learn how to work together as a cohesive team.

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Electrical power is delivered from power generation plants to our homes and busi-nesses through a nationwide network of

electrical distribution equipment including cables, transformers, protective devices, switch-es, 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 ‘computeriz-ing’ 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

off remotely—even if they are not home. Addi-tionally, new products may enable automatic demand response, allowing utilities to automati-cally 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 coun-try. 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 standardsThe National Institute of Standards and Tech-

nology (NIST) is a government agency founded in 1901 whose mission is to advance measure-ment 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 (Inter-net protocols), smart car plug standards, pricing standards, meter output, and a home appliance communication protocol. In fact, NIST is cur-rently working on 20 different Priority Action Plans (PAPs). This is just the tip of the iceberg. It is estimated that hundreds of standards will

By Mark Fisher, Pe, LeeD aP, Alfa Tech, San Jose, Calif.

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.

Codes & Standards

Connecting buildings to the Smart GridEngineers 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.

CSE1212_CODES_V4msFINAL.indd 19 12/5/12 11:34 AM

be required to build an effective and effi-cient Smart Grid.

Many of the standards involve com-municating information and developing demand response capabilities. Typical standards include Wireless and Power Line Communication for the Smart Grid, Electric Storage Interconnection Guide-lines, and Wind Plant Communications.

A NIST standard that directly affects today’s building designers is the electric vehicle plug standards entitled “Com-mon Object Models for Electric Trans-portation.” 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 charg-ing 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 manu-facturers of electrical distribution equip-ment offer a compliant charging station.

Approved standardsSpecifiers of electrical equipment

need to make sure that the products they are promoting meet required stan-dards. As Smart Grid technology is in its infancy, there are not a lot of standards available to guide specifiers.

The Energy Independence and Securi-ty Act of 2007 gave the responsibility for adopting NIST recommended standards to the Federal Energy Regulatory Com-mission (FERC). To date, FERC has not adopted any of the recommended stan-dards, although it has reviewed and com-

mented on several NIST proposals. In addition, the Government Accountabil-ity 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 incom-patibility issues associated with a lack of

standards? Independent agencies such as ASHRAE, National Electrical Manufac-turers 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, Facil-ity Smart Grid Information Model. As noted on ASHRAE’s website, the “pro-posed 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 com-munication 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 Manu-facturers (AHAM) has also started to review standards and make recommen-

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 recom-mended various features that appliances should have for interaction of the Smart Grid with consumers.

The Institute for Electrical and Elec-tronics Engineers (IEEE) has developed more than 20 Smart Grid related stan-dards covering everything from Control of Small Hydroelectric Plants to Collect-ing 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 effec-tively communicate, allowing the Smart Grid to maximize its potential.

Smart Grid-ready productsThere are a number of available Smart

Grid-ready products and services that affect building and facility designers. These include direct load control devic-es, Web portals for automated metering via the Internet, in-home displays, and programmable communicating thermo-stats.

Mark Fisher is head of the electrical department at Alfa Tech Consulting Enterprises. His expertise is in sustain-able design, and he has written white papers on plug load reduction and com-mercial kitchen energy reduction. He is a member of the California Division of the State Architect’s Green Committee and the Illuminating Engineering Society’s Library Lighting Committee.

Codes & Standards

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.



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A basic definition of an air han-dling unit (AHU) might be “a box with a fan, coils, and fil-

ters.” From there it gets considerably more complicated. Proper selection of an air handler requires answering myriad questions ranging from “what capabili-ties 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, it’s important to realize that there will not be a “perfect” selection for any AHU as many competing criteria, not the least

being cost, will force compromises. It is the engineer’s 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 informa-tion 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 pri-marily to large AHUs, the general consid-erations 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

Air handling units come in all shapes and sizes. Learn to balance andprioritize 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.

How to selectan air handling unit

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Types of AHUsFan 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 typi-cally less efficient than larger AHUs and have difficulty providing tight temperature and humidity control.

Packaged AHUs are very common in smaller buildings and commercial applica-tions, particularly as rooftop units. Pack-aged units generally contain fans, coils, filters, and dampers in a single casing. Often the casing includes its own air con-ditioning compressors and means for heat-ing such as gas burners, electric heating coils, or heat pump coils. They often serve single temperature zones, but large vari-able air volume (VAV) AHUs serving mul-tiple terminal boxes (zones) are available. Because of their compactness and lower initial costs, packaged units have a reputa-tion 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. Mod-ules are assembled at the factory or can be shipped individually and assembled on-site. Modular units generally allow great flexibility and can meet most air process-ing requirements.

Custom AHUs are available in near-ly any configuration that a user might require. They generally have the highest quality construction and are most com-monly used in institutional or industrial applications where high flow rates, very close control, and harsh conditions exist. They may also be applied in irregu-lar spaces that would not conform to a

modular line. Custom units can be config-ured 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 dis-cussed, but can be expected to have the longest lifespan.

Anatomy of an AHUCasing 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 ther-mal bridging) is available from a variety of manufacturers and generally has bet-ter 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 out-side 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 contami-nants 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 filter’s 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

Figure 2: This building information model (BIM) rendering shows a multi-story office building’s HVAC ductwork and piping. This image was generated approximately half-way through the design process and identified areas of the design that required addi-tional coordination. Autodesk’s Revit and Navisworks programs were used to render this. Courtesy: H&A Architects and Engineers


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is expected that a similar approach will adopted in the United States in the com-ing years.

The lifecycle cost of filters should be carefully considered during the design and subsequent purchasing of the filters. Over-all, 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. It’s also extremely impor-tant not to skimp on access space. If an AHU is difficult to access and filters are difficult to reach, they won’t 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 building’s total annual energy usage. The supply fan push-es 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 significant—to be removed from the

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 see-ing increased application in low-temperature air systems.

Fan selectionThere 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, pro-vides maximum fan power restrictions on HVAC systems based on the flow rate and a variety of factors related to applica-tion 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 mini-mum 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. It’s always impor-tant 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 perfor-mance.

Coils: Coils are used to heat, cool, and dehumidify air. The heat source can be from hot water, steam, electric-resis-tance, or hot refrigerant vapor (as with a heat pump). Cooling and dehumidification can be provided via expansion of refriger-ant (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 air’s humidity.

Access: Access sections are frequent-ly omitted from AHUs either through designer oversight or intentionally due to

It is the engineer’s job to balance and prioritize all of the decisions to select a unit for a given application.

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. Cour-tesy: Buffalo Air Handling

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



space or budget restrictions. But skimp-ing on access can prove shortsighted as each component within an air hander will require routine service, repair, or replace-ment many times over the life of the unit. Coils must be cleaned frequently to main-tain proper heat transfer, and they must be accessible from front and back to do so. The more difficult it is to reach a com-ponent, the less likely maintenance will be performed, which will result in lower overall efficiency and reduced longevity.

Humidifiers: There are numerous meth-ods for delivering humidification, includ-ing steam, ultrasonic dispersion, infrared heating, and atomization of water. Care-ful consideration is necessary to determine which method is best suited for a given project, but humidifiers in general are maintenance intensive. They must there-fore be installed in easily accessible loca-tions since serious damage and IAQ issues can arise if humidifiers are not operating properly for extended periods.

Codes and standards 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 Internation-al Energy Conservation Code (IECC), ASHRAE 90.1, and California Energy

Commission’s 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 fed-eral projects requiring new buildings to operate with much less energy than mini-mally code-compliant ones. The U.S. Green Building Council’s 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 Construc-tion Code (IgCC) and ASHRAE Standard 189.1 also tighten energy performance and are being increasingly adopted by states and localities.

Multiple organizations provide stan-dards for the testing, rating, and instal-lation of AHUs and associated compo-nents. Some examples of these include Air Movement and Control Assn. (AMCA),

The LEED rating system requires new buildings to have at least 10% less annual energy costs than a code-compliant building.

Figure 5: The curves define fan efficiency grade (FEG) as function of fan wheel diam-eter and a fan’s total peak efficiency. Note that peak total efficiency (%) can be very different than a fan’s FEG, especially with smaller-diameter fans. Courtesy: Air Move-ment and Control Association (AMCA) International Standard 205-2012

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.

� Don’t 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.

Design tips


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International, Air-Conditioning, Heat-ing, and Refrigeration Institute (AHRI), ASHRAE, and Sheet Metal and Air Con-ditioning Contractors National Assn. (SMACNA). These organizations pro-duce 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 mainte-nance for air handling equipment.

Emerging trends in AHUsAlthough much of the technology in

AHUs has remained relatively unchanged for decades, some relatively new compo-nents 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 typical-ly 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, direct-drive 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 energy-efficient 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, counter-flow arrangement. Successful application is dependent on many factors, most impor-tantly climate. It is generally easiest and most cost effective to apply when dedi-cated outside air units are used.

Dedicated outside air units are increas-ingly being applied in lieu of traditional air

Figure 6: This is a view of supplyfan array within an AHU. Fansare direct-drive plenum type.Variable frequency drives areinstalled at the factory. Courtesy:Buffalo Air Handling

CSE1212_FHVAC_V8msFINAL.indd 27 12/5/12 11:36 AMCSE121201-MAG_Ads.indd 27 12/5/2012 3:00:45 PM


units that mix outdoor air and return air. For many climates, the toughest part of an AHU’s 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 air’s dewpoint even if the occupancy of the building might not require such low temperatures to meet space temperature setpoints. The mix-ing dampers and their associated control sequences in AHUs are common modes of failure, which together with sensor drift can result in over-ventilation (higher ener-gy use) or under-ventilation (poor IAQ).

A better approach for many buildings is consolidating all of the outdoor air treat-ment into dedicated AHUs that supply 100% outdoor air. Treated air (dehumidi-fied 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 cli-mates, 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 cool-ing towers.

Training is also an important compo-nent of commissioning. System operators must be properly trained to understand all operating modes of each piece of equip-ment. Training materials must be left on-site so that new personnel can come up to speed easily.

Energy use comparison 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

Every project carries with it a unique set of criteria that must be balanced to arrive at the best (not perfect) solution.

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

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 efficien-cy motor, and a static pressure reduction of 0.5 in. wc—easily achievable through careful AHU and duct system design.

The results show a total energy reduc-tion 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.

ConclusionThe preceding information is necessar-

ily 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 eco-nomic analysis is usually required to sup-port the ultimate path forward.

Each individual component within an AHU must be selected with a combina-tion of research, analysis, and experience. By keeping energy efficiency and main-tainability 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 building’s operators to keep them running well. Preventive maintenance programs together with continuous commissioning will help ensure the lowest possible own-ership cost for any system.

Rob McAtee is vice president and mechani-cal department head and has more than 20 years of experience in energy and build-ing systems. Evan Riley has more than 10 years of experience in design, commission-ing, and modeling of HVAC systems.

Table 1: Fan energy comparison: Good versus betterBase-case:

ASHRAE 90.1-2007 compliant

fan

Alternate: FEG = 75, reduced static pressure, direct

drive

Fan efficiency grade (FEG) 67 75

Fan efficiency based on wheel size and FEG 63% 71%

Drive type Belt with VFD Direct with VFD

Relative drive loss 1 3% 0%

Fan efficiency including drive loss 60% 71%

Motor efficiency level EPAct NEMA Premium

Motor efficiency 93.0% 94.1%

Building energy use (electrical MWh) 2073 2008

Building energy use (gas MBtu) 1020 1010

Fan energy use (electrical MWh) 218.8 164.5

Fan energy cost $18,831 $14,085

Total building energy savings 2 1.8%

Total building energy cost savings 2 3.4%

Notes1. 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.


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The design is complete; now it’s 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 descriptionMost experienced lighting designers and

engineers find that the luminaire descrip-tion is the key to getting the proper prod-uct. 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?

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By following a few guidelines, engineers and lighting designers can specify an appropriate lighting system for a facility.

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CSE1212_FLIGHT_V6msFINAL.indd 30 12/5/12 11:38 AM


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 transi-tional 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 competi-tion 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 you’ve created a one-manufacturer specification, which could be problematic if it’s a competitive bid project. A descrip-tion 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 don’t require an extensive description because there aren’t 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 perfor-mance and price: recessed 2x4-ft lensed troffer with #12 pattern acrylic lens.

If you’re 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,

such as house side shield in the shoe box or wire cages for your strip lights.

One final note: It’s easy to copy and paste from an old schedule, but if you don’t review your descriptions, you might just find the 2x4-ft lensed troffer that the project needed showed up as a 2x4-ft lou-vered troffer.

Lamps/LEDAren’t all lamps the same? No, not all

lamps are created equal; they’re not even equal among the same manufacturer. Sev-eral manufacturers have two or three different quali-ty levels among each of the lamp styles. Did you know that the linear fluorescent700 series phosphor lamps not only have lower CRI but also produce fewer lumens than the same wattage 800 series lamps? Does your project require good color rendering? If it does, then the 700 series lamps are not an option for you, only the 800 series are. Is the project planning on getting any energy credits or rebates? Is it planning on using the low-wattage linear lamps? Does your design take into account the lower lumen output for the lamps? There are a lot of fluorescent lamp questions that need to be asked and answered prior specification.

Once you answer these and other ques-tions, the selection process can begin. As

with most things it is best to stick with what is familiar; Osram, GE, and Philips are the main competitors in the lamp mar-ket and should be considered first. If these manufactures can’t 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, watt-age, and color temperature. Telling a con-tractor to provide a 32 W lamp is only giving part of the necessary information and can lead to some very strange sub-

mittals. There are 32 W fluorescent lamps avail-able in linear, compact, and u-bend forms. Which form meets your require-ments? Color temperature and CRI should always be listed as part of the lamp specification or as part of the general notes in your luminaire schedule. This will help ensure that the

color temperature for all the lamps on the project will match. There is nothing more embarrassing than walking through your project and seeing several different colored lamps just to find that you didn’t specify a color temperature.

Choosing an HID lamp involves some of the same considerations as choosing fluorescent lamps: shape, wattage, and color temperature. In addition to these, think about lamp base, lamp orientation,

Learningobjectives� Understand which light-ing type is correct for each application

� Know which energy codes pertain to the project

� Know how to write the specification to get the achieved light.

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



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 lamp—a vast improvement over

the 500 K to 800 K that we saw during the 1980s and 1990s.

Due to this color stability, HID lamps aren’t just for the parking lot or ware-house 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 eas-ily replace a 50 W halogen in light output with significant energy savings, rated life, and quality of light. Many other low-watt-age 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 distri-bution. Similarly, if you are illuminating a parking lot, the shape of the 400 W HID lamp will dictate the available reflector

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

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 watt-ages 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 applica-tion. 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 Engi-neering Society (IES) file and make sure to pay attention to the color temperature

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/driverBallasts are by far one of the most chal-

lenging sections of the schedule. Why? Because there are so many variables: electronic, magnetic, program start, rapid start, pulse start, low ballast factor, dim-ming, and more. There are many different manufacturers for each type of ballast. Visit the websites of various manufactur-ers to obtain information: GE, Sylvania, Philips, Fulham, Vossloh-Schwabe, Rob-ertson, and Hatch.

So where do you start? If you live in an area that has a local energy code, such as California’s 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 stan-dard, engineers can automatically narrow the search to companies with strong back-grounds in the industry and that have the collective goal of making energy-efficient products. If you are specifying compact fluorescent or T5 lamps, you can’t always find the ballast necessary for your project on the NEMA list. For these lamps, it is still advisable to use the same manufactur-ers that are part of the NEMA program. The items that should be reviewed before making a ballast selection are ballast fac-tor, 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

Due to the potential for “nonpassive failure” some HID lamps are safe only in enclosed luminaires.

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


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Not all lamps are created equal; they’re not even equal among the same manufacturer.

“normal” ballast factor of 0.85 provides 85% of the lamp’s 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 fac-tors 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 bal-last 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 ener-gy 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 digi-tal 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 impor-tant to know what is required for your project. For LED luminaires there are different levels for dimming, from those that don’t dim to those that dim to 10%. Currently there are very few LED lumi-naires 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

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 bal-lasts: Just because you specify a particular ballast doesn’t mean it is going to fit in your luminaire. Not all ballast manufactur-ers list the housing size for their ballasts, and when they do list the size it doesn’t mean the ballast will fit into the luminaire. In these cases the manufacturer’s repre-sentative 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 bal-lasts cover a wide range of lamp watt-ages, up to 1000 W. The Energy Indepen-dence 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 specifica-tion of metal halide systems.

Magnetic probe start metal halide lamp ballasts are still available in wattages higher

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


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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 informationThis is the final step in a good specifica-

tion, and at our firm it is the most conten-tious. 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 example—architectural recessed round aperture dimmable LED downlight nominal 6-in. diameter aper-ture by 6.75-in.-high steel housing with extruded aluminum heat-sink matte clear reflector with convex transitional lens. This description is based around Portfo-lio’s LD6x series LED recessed downlight.

To this point, we have discussed the luminaire description, lamping, and bal-lasts, 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 doesn’t mean that they are not important, but we should assume that each luminaire sched-ule 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 “manufactur-ers” section? If we list it again as part of a complete catalog number (LD615D010 ERM6835 6ML1WMH), who is respon-sible 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 manufactur-er’s 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 dis-claimer tells me that there is a chance something in that catalog number will change between when I specify the proj-ect and when the product is ordered. This means that the electrical contractor has to interpret the designer’s 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 informa-tion. 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 hos-pitality, high-end custom homes, offices, retail, schools, and healthcare facilities. Larsen has provided lighting and daylight-ing 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. Cour-tesy: Mark Godfrey, Interface Engineering


40 Under 40: The Consulting-Specifying Engineer 40 Under 40 program was born out of Consulting-Specifying Engineer’s ongoing mission to foster mentoring in the engineering industry. 40 of the most talented young engineers supporting the building community are nominated by their mentors and honored throughout the year in print, online, and in person.

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Product of the Year: 2012 marks the 8th year that Consulting-Specifying Engineer holds the annual Product of the Year (POY) contest. It is the premier award for new products in the HVAC, fi re, electrical, and plumbing systems engineering markets. Look for the POY winners online at www.csemag.com/POY.

Giants: The MEP Giants contest features the top MEP fi rms, listed by total MEP design revenue. For 32 years, the MEP Giants list is used by many engineering fi rms to track their growth and prominence within the MEP Engineering industry. Please look for the full MEP Giants special feature on www.csemag.com/giants.

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Want 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, engi-neers can offer their clients more options. In today’s environment of ever-changing technology and increasingly more strin-gent energy codes, flexibility is more valuable than ever. Many of these wire-less controls use miniature batteries with a claimed life of up to 10 years; some

don’t 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 con-trols have been around for a long time, but now that wireless has become per-sonalized (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 Connectn 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 rout-ers) 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 area—provides superior response time from devices.

n Protocol is optimized for long battery life.

n In market since the late 1990s.

Figure 1: This demonstrates the flexibil-ity of being able to mount wireless sen-sors practically anywhere. It’s not typical to see a temperature sensor mounted on an office cubicle wall as depicted in this image. Courtesy: Trane, a brand of Ingersoll Rand

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.

Wireless building controls

CSE1212_FELEC_V7msFINAL.indd 38 12/5/12 11:39 AM


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 harvesting—wire-less 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.

ZigBee� ZigBee is a registered trademark of

the ZigBee Alliance, a non-profit associa-tion of manufacturers, which maintains the ZigBee Standard.

� Manufacturers have to become a member to make and market ZigBee prod-ucts for commercial use.

� Operates primarily on 2.4 GHz (worldwide frequency), but 915 MHz and 868 MHz also available.

� Built on and uses physical and access lay-ers of the IEEE 802.15.4–2003 protocol.

� First standard—called ZigBee 2004—has been around since 2005 and has been updated and revised several times since publi-cation.

� The ZigBee Alliance sets and publishes Appli-cation Profiles to help manufacturers make interoperable products, including:

- ZigBee Commercial Building Automation - ZigBee Home Automation- ZigBee Smart Energy 1.0- ZigBee Telecommunication Ser-vices- ZigBee Health Care- ZigBee RF4CE - Remote Control

� It is important to note that to ensure interoperability between various devices

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: ret-rofit costs, flexibility costs, and occupant comfort.

Cost considerationsHardware costs: Hardware costs for

items like switches, conduit, boxes, wire (low voltage of 12 to 24 V and line voltage

of 120 to 277 V), occupan-cy sensors/power packs, and temperature sensors can add up quickly. The hardware costs for the wireless devices typically will be greater than the costs for the wired coun-terparts they are replacing.

Soft costs: Cost sav-ings for items like occu-pant comfort and control are harder to quantify cost-wise. However, it is not a stretch to attribute

occupant comfort to increased produc-tivity and company retention rates. For example, consider a large, open office space with cubicles where the only per-manent walls are around the perimeter of the space (sometimes these are movable walls that are part of the office furniture system; see Figure 1). It is quite common to place temperature sensors around the perimeter, hardwired in the permanent walls. In many cases, temperature sen-sors for different zones are placed on the

wall next to each other to help save on construction costs. But when a tempera-ture sensor is not located in the zone that the HVAC system serves, inaccurate tem-perature sensing can result in the actual location where the HVAC unit is provid-ing 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 employee’s cubicle. Lighting controls with dimming and personal control at each workstation also help to improve employ-ee comfort and productivity.

Employee comfort has a definite cor-relation to productivity and retention rates for companies, as shown in a white paper

Learningobjectives� Better understand some of the more common wireless technologies used in building controls

� Learn about common wire-less standards

� Identify the potential cost savings, construction effi-ciencies, and flexibility that wireless controls can bring to a building

Adhering toenergy codes

ASHRAE Standard 90.1-2010, Energy Standard for Buildings Except Low-Rise Residential Build-ings, 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 cer-tify that the provisions of the state’s 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 15- and 20-Amp receptacles, including those installed in modular partitions, installed in the following space types:

a. Private officesb. Open officesc. Computer classrooms

shall be controlled by an automatic control device that shall function on:

a. A scheduled basis using a time-of-day operat-ed control device that turns receptacles off at spe-cific programmed times—an 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.


In the Great Smoky Mountains National Park in North Carolina, the Harrah’s 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 Trane’s WTS series wireless temperature sensors with an esti-mated 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.

Casino expansion goes wireless

Figure 2: The wireless temperature sen-sor can be used in environments where occupants are not allowed any local control of the occupied space. The WZS wireless zone sensor allows occu-pants limited local control of tempera-ture settings and the ability to override the system’s settings at any given time as space becomes occupied or unoc-cupied. 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


titled “Environmental Satisfaction, Per-sonal Control, and the Positive Correla-tion 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% pro-ductivity 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 build-ing 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 building’s operating costs because the employee costs are significantly higher.

Flexibility: Flexibility cost savings can be encountered not only during but

By leveraging the flexibility of wireless control devices, engineers can offer their clients more options.

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 com-plete building or space renovations. Wire-less 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 mea-sured 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 construc-tion, many hours can be spent on coordi-nating these rough-ins so that they don’t 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 con-struction, each device location is touched

only once for the final instal-lation. 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 con-tractors 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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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 drasti-cally 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., switch-es, 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 fre-quency (RF) study may be warranted to ensure proper wireless penetration.

ConclusionWhen the traditional hardwired sys-

tem approach is compared to a wireless approach, accounting for all wireless hard-ware costs and all other cost savings, the overall installed cost for a wireless solu-tion 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 coun-terparts. 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. Sen-sor 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 consider-ations. There may be buildings where this risk is not feasible.

Cost savings will always vary based on the project type, local labor rates,

and how well the contractors are edu-cated on the efficiencies of using of wireless technologies. For medium to large projects, Trane reports that its wire-less solution is priced to save an aver-age of 10% of the installed price com-pared to a traditional wired solution. This does not include the soft or flexibility costs that can be further achieved through-out the building’s 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 mate-rials). The overall project, including fix-tures 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 dur-ing 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 techni-cal specifications and building designs in the hospitality, entertainment, and mission critical fields.


CSE1212_FELEC_V7msFINAL.indd 41 12/5/12 11:39 AMCSE121201-MAG_Ads.indd 41 12/5/2012 3:04:29 PM


The phrase “integrated MEP con-trol systems” generates images of holistic design where all com-

ponents of the mechanical, electrical, plumbing (MEP), and fire protection systems work in harmony. Unfortunate-ly, industry professionals see far too many mission critical facilities (MCFs) in which MEP systems are joined by a menagerie of control systems and pro-tocols 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 imple-mentation.

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 commis-sioning begins at the planning phase of a project, the questions and insights gained from experience in commission-ing MCFs contribute the greatest value to meeting project objectives and sav-ing 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 ulti-mately the whole facility, is tested. Cour-tesy: Primary Integration Solutions

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.

Commissioning control systems for MCFs

CSE1212_FMCF_V6msFINAL.indd 42 12/5/12 11:40 AM


money. Here are eight key issues and insights at each phase of an MEP control integration project.

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 inte-gration project: a concise written defini-tion of project goals in operational and performance terms; and the right deci-sions 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 pos-sible, and put them in a concise, writ-ten owner’s project requirements (OPR) document.

The document should identify and define the owner’s operational and per-formance objectives in detail. For exam-ple, operational details might include the owner’s requirement for real-time communication of system operating data to staff of a remote, 24/7 network operations center. The owner’s perfor-mance goals might, for example, include key parameters such as refresh time for data reporting. Vetting the requirements through the client’s 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 summa-rizing the typical 100-plus-page pro-gram document into a concise 10-page document that outlines the specific proj-ect 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.

2. Multisystem automation pro-vides the most flexibility.

At the core, there are two ways to inte-grate multiple systems: select a single controls and automation vendor and make it responsible for all aspects of the inte-gration, or use a third-party integration system to connect the various systems, process the data, and present it in a uni-form 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 implemen-tation 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 compro-mised. Switching controls vendors in an operating facility is costly and disruptive.

The third-party integrator introduces another vendor to the project, but pro-vides the most flexibility for the own-er’s 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 dimin-ished, but not disappeared. A CxA may also advise bringing to the planning table a third-party integration consultant. To ensure objectivity, specify that the con-sultant is ineligible to bid the implemen-tation contract.

3. Network architecture: Two net-works are better than one.

Historically, MEP control and automa-tion networks were set up on a dedicated network infrastructure physically sepa-rated 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 proto-cols and data types being carried by all

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 single-network architecture. Time and money would have been saved had the potential drawbacks been anticipated by all mem-bers 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 deliver-ing a fully integrated MEP control sys-tem in a cost-effective manner. Having a “hands-on” experienced system inte-gration consultant on the design team is usually money well spent. The par-ticipation of this profession will ensure that design and specifications are practi-cal, 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 phase—or 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. Sim-plification 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 docu-ments is a singular meaning. Leave no room for multiple interpretations. Ide-ally, invite both experienced industry professionals and stakeholders, such as



the MEP operators, to review the docu-ments for completeness and singular meaning.

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 pro-grammers’ own approach. From expe-rience as a CxA, this approach creates multiple opportunities for problems during implementation and through-out the entire lifecycle of the system. Ideally, criteria for control system vendor selection should include the

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 addi-tions tracked in a version control system that supports restoration of the stored code to various points in the develop-ment 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 mock-

ups for the facility’s staff to review and accept before code development begins in earnest. This enables the initial develop-ment of the code to more closely meet final requirements on the initial pass, sav-ing rework and time later.

Similarly, specify that the controls con-tractor 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 client’s requirements.

6. Implementation: Factory testing saves time.

Successful integration of MEP control systems depends on effective independent commissioning and proper implementation.

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 sys-tem communications, and highlights key revisions to the plan. Courtesy: Primary Integration Solutions



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 pro-cedure. The engineer and CxA should review the procedure prior to testing. Schedule the factory acceptance test to allow the engineer, CxA, and facility’s 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 get-ting user feedback before delivery to the site reduces field modifications and the potential errors that they introduce.

7. On-site testing and commission-ing starts at the component level.

The process for testing and commis-sioning 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 con-trols will be one of the last items on the schedule; however, this does not relieve the installer from completing proper test-ing of all installed components via point-to-point verification and loop checks.

A key concept that is not well under-stood 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.

This wastes time, and mission critical projects rarely have the luxury of wasted time. Before testing the integration of systems, the constituent systems them-selves must be completed: that is, all open items are closed, and a complete, success-ful 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 CxA’s addi-tional time resulting from misreporting completion status.

Here is the recommended commis-sioning 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 infrastruc-ture 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 traf-fic levels.

n Silo system testing: Similarly, sys-tems that have control systems installed by the controls contractor should have comprehensive testing done on all points to ensure proper connections and config-uration within the control system. Some CxAs try to combine OEM and silo sys-tem testing; these should be conducted for each component and then for the over-all 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 detec-tion systems and the HVAC systems. Each scenario that requires that two or more systems operate in a unified man-ner should be simulated and appropriate response verified. Inviting facility staff to participate in these tests is an excel-lent opportunity for the CxA to provide training.

8. Ongoing operation/change con-trol: 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 pro-vide a complete set of updated documents and control code. A lessons-learned ses-sion that includes the construction, com-missioning, and operating staff yields significant knowledge transfer to support ongoing operations.

In addition, having the controls con-tractor periodically return to the site (monthly or quarterly) to work with the facility staff on small system adjust-ments is a good way to ensure that facility operations remain optimized. Changes in setpoints or programming should be updated in the documents.

Figure 3: Verification of all original equipment manufacturer (OEM) controls at each device is a prerequisite of any integration testing. Courtesy: Primary Integration Solutions


Date: 10/15/12 Client: Mee Industries Job #: 08482012

File Name: 0848_MEE_CSE_Dec_2012_Advt_

Account Director: CJ Ramirez Editor:

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MEEFOG BENEFITS

• Signifi cant energy savings

• Improves humidity and temperature control

• Improves equipment reliability and performance

• Reduces HVAC maintenance costs

• Suspends airborne dust

• Reduces CO2 production

• Eliminates static electricity

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Scan to access more information or go to: meefog.com/0848

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Periodic retesting provides a level of assurance that the system’s performance has not degraded over time.

As time progresses and the various sup-pliers issue updates to the on-board con-trollers 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 soft-ware upgrades can be installed at the site. Manufacturers that supply heavily to the mission critical industry are famil-iar 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 recom-missioning of the controls and integration during scheduled maintenance windows will provide a level of assurance that the system’s performance has not degraded over time. CxAs can provide this rela-tively low-cost, high-value service over the lifecycle of the system.

The integration of MEP control sys-tems in a mission critical facility is an exacting and demanding task. Care-ful and deliberate planning, coupled with professional installation, testing, and commissioning, is the only way to achieve a successful outcome. Assem-bling 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 mis-sion 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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SUPPLEMENTAL HEATfor Comfort and Ef� ciency

MAKEUP AIR HEATERSUNIT HEATERS AIR TURNOVER SYSTEMS

plelpGT_Winter2012.indd 1 11/23/2012 1:24:13 PM

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on the cover

Most large industrial buildings

benefi t from supplemental heating

units fueled with clean, effi cient 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 DirectorJake DelwicheContributing EditorComments 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

energy solutions center websites

www.aircompressor.org

www.cleanboiler.org

www.energysolutionscenter.org

www.naturalgaseffi ciency.org

www.gasairconditioning.org

www.poweronsite.org

A6 Natural Gas Vehicle FuelingThe CNG fueling infrastructure is blossoming and beneficiaries include industrial, commercial and transportation companies that operate road vehicles of all kinds.

Find out if there’s a place for natural gas vehicle fueling in your future.

A8 Infrared Imaging on Your Audit TeamToday’s 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.

A10 Microturbine Technology in Today’s 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.

A12 Keep Your Boiler Plant at Its PeakModern 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.

A3 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.

inside


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Supplementary Heat for Industrial Spaces Systems Improve

Ef� ciency, Add Comfort

W W W. E N E R G Y S O L U T I O N S C E N T E R . O R G g a s t e c h n o l o g y / W I N T E R 1 2 A 3

TODAY’S INDUSTRIAL OR WAREHOUSE SPACES are dif-

ferent from other comfort conditioning applications. These build-

ings typically have high ceilings and may have large ventilation

requirements. Depending on the geographic location and the pro-

cesses 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 build-

ing primary heating system could be furnaces, air heaters, radiant

� oors, a steam hydronic system, or even byproduct hydronic heat

from process hot water.

Keeping It PositiveMost industrial buildings can bene� t from supplementary heating

and air� ow equipment. An issue for many facilities is maintaining

correct building pressurization. Today’s stringent industrial venti-

lation 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 un-

� ltered outdoor air into the building that may contaminate man-

ufacturing or food processes and may also be detrimental to em-

ployee 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 NeededWhen 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 won’t 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

direct-� red 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 make-

up 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.

Match Flows to DemandUsually 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.

Rooftop 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


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A 4 g a s t e c h n o l o g y / W I N T E R 1 2 W W W. E N E R G Y S O L U T I O N S C E N T E R . O R G

Cutaway view of the heating function in a direct-fired rooftop makeup air handler.Illustration courtesy Four Seasons Controlled Climates Ltd.

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, wastewa-

ter treatment and other industries where

it is important to maintain building pres-

sures 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 han-

dlers are especially important. “They re-

duce 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.”

Warehouses are DifferentKosar points out that warehouse spaces gen-

erally 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

a requirement as well in industrial facilities

that must maintain speci� c temperature and

humidity ranges for manu-

facturing processes such as

food and beverage, or phar-

maceuticals.”

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 ven-

tilation air for workers, and

a little extra for some posi-

tive pressurization. “That

air� ow combined with the

needed temperature rise

from winter design air tem-

perature will determine the

heating capacity.”

Focus on Speci� cNeedKosar points out that in de-

signing new facilities or ret-

ro� tting existing facilities,

owners should consider iso-

lating outdoor air treatment

to a limited number of spe-

cialized, dedicated outdoor

air systems. “This approach allows energy

ef� ciency technologies to be more cost ef-

fectively applied while delivering improved

facility operations.”

Units can be controlled on both a tem-

perature 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 direct-� red heaters are

available in the larger capacities – up to

100,000 cfm and sometimes more. Com-

monly the design temperature rise is ap-

proximately 60° to 75° F. Because of the

greater weight of indirect-� red units, you

may need to install special structural sup-

ports for such units in rooftop installations.

Advantages to Direct-FiredAccording to John Szymanski from Trane,

a supplier of such equipment, the direct-

Most air turnover units are available with plenum extensions toreach to the ceilings of industrial buildings. Photo courtesy Johnson Air Rotation.


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W W W. E N E R G Y S O L U T I O N S C E N T E R . O R G g a s t e c h n o l o g y / W I N T E R 1 2 A 5

� 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 direct-� red units can also

be ordered in a vertical arrangement. “This

can assist in air turnover for structures

with large � oor to ceiling height like ware-

houses and heavy manufacturing.”

For spaces where outdoor air makeup is

not a primary requirement, another solu-

tion to improve building comfort is dedi-

cated 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 with-

out air rotation, ceiling level air tempera-

tures can be as much as 25 degrees higher

than at the � oor level.

Mixing is the KeyIn 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 ex-

its 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 heat-

ers. These are compact high output units

using gas heating with high-velocity air

distribution by either propeller or cen-

trifugal fans. Unit heaters are a common

solution near high heat-loss areas such as

loading docks or openings to unheated

warehouse space.

Unit Heaters for Spot ComfortUnit heaters are available in either direct-

� red or indirect-� red styles. For maxi-

mum 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 neces-

sary 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 heat-

ers and gas-� red heated air knives for in-

stallation at large open doorways. In all cas-

es, 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 ChoiceTo achieve a comfortable and ef� cient

industrial environment, it is usually nec-

essary 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 ex-

pense by installing the right kind of sup-

plementary heating equipment. GT

M O R E

i n f oCAMBRIDGE ENGINEERINGwww.cambridge-eng.com

GAS TECHNOLOGY INSTITUTEwww.gastechnology.org

GREENHECKwww.greenheck.com

JOHNSON AIR ROTATIONjohnsonairrotation.com

MODINE MANUFACTURING COMPANYwww.modinehvac.com

REZNORwww.rezspec.com

TRANEwww.trane.com

Unit heaters areavailable in a wide range of sizes and can be either directly or indirectly fired. Photo courtesy ModineManufacturing.


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Vehicles such as this City of Milwaukee refuse truck that have high annual mileage and low mpg are idealcandidates for time-fill fueling with CNG.

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. We’ve long understood

its potential. Now the change is underway.

Dissatisfaction with high gasoline and die-

sel fuel costs abound.

Problems with PetroleumToday about 50% of U.S. crude oil comes

from sources outside of the U.S. or Can-

ada. 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 require-

ments have discovered CNG and in some

cases liquid natural gas (LNG) as the fuel of

choice for now and for the future. Retail-

ers are typically selling CNG at a price well

below $2 per GGE.

Infrastructure Under ConstructionThe infrastructure for refueling is devel-

oping. Take the example of a retailer that

is enthusiastic about the future of natu-

ral gas as a motor fuel — Kwik Trip Inc.,

a privately-held � rm headquartered in La

Crosse, Wisconsin with over 400 conve-

nience stores and travel centers in Wiscon-

sin, Minnesota and Iowa.

Kwik Trip representative Chad Hollett

was recently a presenter at a Technology

& Market Assessment Forum sponsored

by the Energy Solutions Center. Kwik Trip

operates the � rst “alternative fuels fuel-

ing station” in the U.S., offering access to

propane, biodiesel, E-85, electric vehicle

charging, LNG and CNG.

Full Range of Fuel OptionsHollett indicated, “Kwik Trip is committed

to developing a functional natural gas in-

frastructure in Wisconsin, Minnesota and

Iowa.” He notes that the company has

already developed two natural gas fuel-

ing sites in La Crosse, Wisconsin and one

each in Sturdevant, Wisconsin (near Mil-

waukee) 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 Trip’s Alternative Fuels Super-

intendent Joel Hirschboeck emphasizes

the company’s focus on development of

a functional infrastructure. “We see great

potential for this as a motor fuel. As we

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.

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 opera-

tions, or if they are just getting into CNG,

they may not want the immediate expense

or uncertainty of a dedicated fueling opera-

tion. “That’s where we come in. We will of-

fer a fast-� ll capability in a convenient loca-

tion 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 ve-

hicles planned for spring delivery. He ex-

plains that the acceptance of the CNG ve-

Natural Gas Vehicles on the Rise


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w w w. e n e r g y S o l u t i o n S c e n t e r . o r g g a s t e c h n o l o g y / w i n t e r 1 2 A 7

more

i n f oDOE 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

Kwik Trip has committed to natural gas fueling for additions to its fleet oftrucks and light-duty vehicles. The company is also developing a network of alternate fueling stations in Wisconsin, Minnesota and Iowa.

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.

hicles by drivers has been excellent. “The

8.9 CNG liter truck engine we use is rela-

tively 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 doesn’t leave

an oily diesel smell on their clothes. And

they like the idea of using a domestic fuel

resource. They feel good about that.”

From the company’s perspective, the

biggest attraction is significantly lower fuel

cost per ton-mile. Hirschboeck adds that

because there are fewer residual combus-

tion byproducts, engines stay cleaner and

lubricating oils last longer. Further, with

future diesel engines, more expensive fuel

treatment and emission controls will be

required.

Short PaybackSimilarly, with light duty vehicles, for

Kwik Trip the first attraction is also low-

er 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 mil-

lion 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 Publicand Private SitesFor some fleet operators the best fueling op-

tion may be an in-house time-fill refueling

station. For operators that have less predict-

able 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 en-

couraging and sponsoring the development

of natural gas vehicles. Davis explained that

the company feels infrastructure develop-

ment is one of the keys to a successful na-

tional adoption of natural gas vehicle use.

I-15 Corridor in UtahIn Utah, there are 72 natural fueling stations,

including 27 operated by Questar and avail-

able for public use. Others are operated by

the State of Utah, and by other private own-

ers. 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 de-

veloping natural gas fueling with a national

scope. The firm offers consultation, design,

installation and leasing for natural gas fuel-

ing stations, both public and private.

Judd Cook is Director,

Business Development

for Questar Fueling. He

says that the I-15 corri-

dor experience shows the

growth potential of natu-

ral 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.

Short PaybacksEncourage TransitionsCook credits the obvi-

ous savings in fuel costs

for fleet operators for

the growing interest in natural gas fuels.

“Many of the customers we are working

with in the heavy duty market are cur-

rently seeing paybacks between 14 and 18

months.” He believes paybacks of two to

three years or less will incent users to con-

vert or purchase new vehicles.

Interest in CNG fueling is growing. Cook

says, “We are currently working with sev-

eral of the nation’s largest trucking compa-

nies who are testing natural gas vehicles.”

Consider the Natural Gas OptionWhether your business is inter-city trucking

or local delivery, refuse pickup or ready mix

delivery, school busing or parts expediting,

there’s 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 buy-

ing your next diesel or gasoline vehicle, con-

sider the third choice — natural gas. GT

Natural Gas Vehicles on the Rise


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Infrared imaging can be performed by a trainedin-house audit team to identify areas of heat loss, failing equipment and steam leaks in an industrial plant. Photo courtesy Fluke.

Use Infrared Imaging For Energy AuditingWith 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 accu-

rately interpreting results are two different

things. You probably can do it, but your

users will need some training, or the exer-

cise may be a complete waste.

Regular AuditsBecoming the NormIncreasingly, facility owners recognize that

energy auditing is not a one-time proce-

dure. It needs to be a continuing routine to

assure that manufacturing processes and

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 of-

ten the case. But an increasing number of

companies are taking advantage of lower

equipment prices and improved infra-

red imaging capabilities to buy their own

equipment and use their own staff.

Companies Offer Rangeof Imaging EquipmentBrad Risser from FLIR was a recent pre-

senter at a Technology & Market Assess-

ment Forum sponsored by the Energy

Solutions Center. FLIR is one of the global

leaders in the manufacture of digital in-

frared 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 iden-

tify heat gradients and spot thermal anom-

alies. He notes, “This technology allows us

to ‘see’ heat.”

Can Quickly Spot ProblemsThe most basic use of a digital infrared

camera with an on-board screen is to al-

low the user to spot anomalies in a man-

ufacturing or mechanical room such as

overheated bearings, belt rubs, failing pipe

or � tting insulation, hot electrical connec-

tions, bad switches, overheated motors, or

steam and condensate leaks. The point-

and-shoot camera is ideal for these appli-

cations.

In addition to process applications, the

camera can be used to evaluate building

energy concerns by identifying uninsu-

lated areas, leaky windows and doors, wa-

ter 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.

Camera and TrainingVary with PurposeGary Orlove is an application engineer

with FLIR and is curriculum manager for

FLIR’s infrared camera training activities.

He says that the choice of cameras and

the amount of training varies with the in-


creo

tended application. “It depends on several

factors: How much is the auditor’s time

worth? What type of equipment is being

evaluated, what resolution is needed on

the equipment surface, and what tempera-

ture 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 pho-

tographer can use an inexpensive camera,

but the results would be better with a bet-

ter 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.”

In-Depth Trainingfor Detailed AnalysisOrlove 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 calcu-

late energy losses and savings? For the lat-

ter, a minimum of 32 hours of classroom

and a couple of weeks of hands-on experi-

ence 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

at customer sites. We offer all three. Be-

yond the basics on using the camera, the

courses include interpretation of the image

and procedures for correct temperature

measurement.” While some energy calcu-

lations are taught at the infrared class, the

majority of that training is usually includ-

ed in the auditor’s general energy auditing

learning program.

Images Can Be Stored,TransferredOrlove 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.

Fluke Offers Combination ImagingFluke is a broad spectrum manufacturer of

electronic test tools and also offers a line of

digital thermal imaging cameras. An inter-

esting feature available on some of the im-

aging 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 re-

ports on audit results.

In addition to general purpose infra-

red imagers, Fluke offers point-and-shoot

imagers designed for process applications

as well as units designed specifically for

building efficiency analysis. Fluke also em-

phasizes the importance of training for us-

ers of infrared imagers, and offers online

basic and in-depth training courses and

webinars, as well as training classes con-

ducted by Fluke’s training partner, The

Snell Group. Classes are set for multiple

training levels.

Include Training in Your PlansA wide range of thermal imaging products

are now available from multiple manufac-

turers. Whether your interest is doing oc-

casional 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

more

i n f oFLIR www.flir.com/US

Fluke www.fluke.com/fluke/usen/products/ categoryti.htm

w w w. e n e r g y S o l u t i o n S c e n t e r . o r g g a s t e c h n o l o g y / w i n t e r 1 2 A 9

Use Infrared Imaging For Energy AuditingBuilding efficiencycan be checked. This infrared image shows an area of moisture penetration in roof insulation. Photo courtesy Drysdale & Associates.


creo

IT’S 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 — al-

most any thermal application. If you have surplus electric capac-

ity, it can be sold back to your utility. That’s the promise with

combined heat and power (CHP) installations, and one attractive

option is microturbines. These are sometimes called “aeroderiva-

tive” 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.

Growing in Size and FlexibilityToday’s 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 coor-

dinated 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 tem-

peratures 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 sup-

port 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 ab-

sorption chillers for building or process cooling.

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 world-

wide, 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 spon-

sored by the Energy Solutions Center.

Green Energy SolutionIn his presentation, he emphasized that microturbines are a green

energy solution for several reasons. First, they typically burn ei-

ther 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 genera-

tion 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 di-

gesters. He indicated that world reserves of natural gas are three

times those of petroleum.

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 loca-

tions around the world serving many types of heat and electric

loads, microturbine technology is in the mainstream and an at-

tractive solution for many types of users. He indicated that typi-

cally owners size their installation to meet their thermal require-

ment, 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.”

MICROTURBINESPower Plus Heat with Reliability, Ef� ciency IN THE NEWS

Cutaway view of microturbine sections.Illustration courtesy FlexEnergy.

A 1 0 g a s t e c h n o l o g y / W I N T E R 1 2 W W W. E N E R G Y S O L U T I O N S C E N T E R . O R G


Serving Critical Winery LoadAn 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 microtur-

bines for use in industrial, institutional

and commercial settings. This company

acquired Ingersoll Rand Energy Systems in

2010 and is headquartered in Irvine, Cali-

fornia, with a worldwide spare parts depot

at that location. Gas turbine production

and assembly is done at its plant in Ports-

mouth, New Hampshire.

Wide Range of ApplicationsAccording 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 we’ve done, own-

ers want to take full advantage of the ther-

mal 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 ex-

haust 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 ap-

plications that require hot air, hot water,

steam or chilled water.

Medical Center Reduces DemandChargesAn example of an institutional user of micro-

turbines 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

generates 3.3 million Btu per hour of thermal

energy for water heating and meets rigorous

CARB emission requirements. The medical

center’s goal was a system with high reliability

and minimal maintenance.

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 engi-

neer 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 us-

ing fuel resources more ef� ciently, while

reducing emissions and lowering your

contribution to greenhouse gases. Give it

some thought. GT

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.

W W W. E N E R G Y S O L U T I O N S C E N T E R . O R G g a s t e c h n o l o g y / W I N T E R 1 2 A 1 1

MORE

i n f oCAPSTONE TURBINE CORPORATIONwww.capstoneturbine.com

DOE INFORMATION ON MICROTURBINESwww1.eere.energy.gov/manufacturing/ distributedenergy/microturbines.html

ENERGY SOLUTIONS CENTER INFORMATION ON MICROTURBINESwww.energysolutionscenter.org/gas_solutions/ microturbines.aspx

FLEXENERGYwww.� exenergy.com


creo

TOO OFTEN A HIGH-EFFICIENCY package boiler is pur-

chased at a premium price and then allowed to decline in per-

formance from lack of proper maintenance or from incorrect

operation. Today’s boilers are rugged and � nely-tuned machines.

Digital burner controls and on-board � ue gas analysis make the

job easier, but it’s as important as ever to keep an eye on the goal

of optimum ef� ciency.

Feedwater is CriticalPerhaps the single most important item to watch is feedwater

quality. Good feedwater is critical for the life and ef� cient opera-

tion 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 peri-

odic 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.

Keep Controls in CalibrationZala also points out that newer boiler controls often use an O2

sensor to optimize combustion. This means many fewer adjust-

ments of draft and fuel linkages are needed than with older me-

chanical controls. However, he says, “Typically the sensor requires

periodic calibration. Some control systems are designed to per-

form automatic calibration.” Check with the control system pro-

vider 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 im-

portance 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. Typ-

ically you want excess air less than 15% and no measurable car-

bon 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.

Find the Sweet Spot and Stay ThereMost steam boilers have ef� ciency “sweet spots” when � ring

somewhere between 60% and 80% of maximum capacity. Con-

densing 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 informa-

tion 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 unac-

ceptable number of times a day. This hurts year-round ef� ciency.

A Place for PoniesThe solution may be a small “pony” boiler for off-season mini-

mum 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. Doesn’t it

make sense to closely watch the ef� ciency of this system and try

for the best? GT

Maintaining Ef� ciency Is a Continuing Goal

A 1 2 g a s t e c h n o l o g y / W I N T E R 1 2 W W W. E N E R G Y S O L U T I O N S C E N T E R . O R G

CLEAVER-BROOKSwww.cleaver-brooks.com

DOE ON BOILER EFFICIENCYwww1.eere.energy.gov/manufacturing/tech

HURST BOILER & WELDING CO.www.hurstboiler.com

MIURA BOILERwww.miuraboiler.com

M O R E

i n f o

Run Your Boiler at Its Best

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.


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PUBLICATION SERVICESJim Langhenry,Co-Founder and Publisher, CFE Media630-571-4070, x2203; [email protected]

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Trudy Kelly, Executive Assistant630-571-4070, x2205, [email protected]

Elena Moeller-Younger, Marketing Manager630-571-4070, x2215; [email protected]

Michael Smith, Creative Director630-779-8910, [email protected]

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letters to the editor Please e-mail us your opinions [email protected] 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: [email protected].

REPRINTSFor custom reprints or electronic usage, contact: Wright’s Media – Nick IademarcoPhone: 877-652-5295 ext. 102Email: [email protected]

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63

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PUBLICATION SERVICESJim Langhenry,Co-Founder and Publisher, CFE Media630-571-4070, x2203; [email protected]

Steve Rourke, Co-Founder, CFE Media630-571-4070, x2204, [email protected]

Trudy Kelly, Executive Assistant630-571-4070, x2205, [email protected]

Elena Moeller-Younger, Marketing Manager630-571-4070, x2215; [email protected]

Michael Smith, Creative Director630-779-8910, [email protected]

Paul Brouch, Web Production Manager630-571-4070, x2208, [email protected]

Michael Rotz, Print Production Manager717-766-0211 x4207, Fax: [email protected]

Karie Burt, Account Director, U.S. Sales212-584-9374; [email protected]

Rick Ellis, Audience Management DirectorPhone: 303-246-1250; [email protected]

letters to the editor Please e-mail us your opinions [email protected] 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: [email protected].

REPRINTSFor custom reprints or electronic usage, contact: Wright’s Media – Nick IademarcoPhone: 877-652-5295 ext. 102Email: [email protected]

PUBLICATION SALESMidwestMatt Waddell [email protected] West 22nd St. Suite 250 Tel. 312-961-6840Oak Brook, Illinois 60523 Fax 630-214-4504

(AL)Patrick Lynch, [email protected] W. 22nd St. Suite 250, 630-571-4070 x2210Oak Brook, IL 60523 Fax. 630-214-4504

West, TX, OKTom Corcoran, [email protected] W. 22nd St. Suite 250, Tel. 215-275-6420Oak Brook, IL 60523 Fax. 484-631-0598

NortheastRichard A. Groth Jr. [email protected] Pine Street Tel. 774-277-7266Franklin, MA 02038 Fax 508-590-0432

InternationalStuart Smith, [email protected] Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588

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CSE1212_ADINDEX_V2msREVIEW.indd 63 12/5/12 11:45 AM


Back in 1969 when Rolf Jensen founded his fire protection engineer-ing firm, Rolf Jensen & Associates,

the center of the universe was Chicago, our headquarters city. In the beginning, our clients were Chicago-based architec-ture and engineering (A&E) firms that needed RJA’s expertise in code consulting in order to achieve their innovative build-ing 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 firm’s globalization process has come with many “lessons learned.”

Support your clients globally 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 the world. For example, as the market in China started to emerge, we opened an office in Shanghai and started building a relationship with the Chinese fire officials. When our clients began arriving to do work in China, we were already established there and were able to provide them with a combination of local knowledge and techni-cal expertise. We’ve repeated this strategy as we opened offices in other global locations.

Deploy your technical resources as a teamIn engineering consulting firms, the most important

resources are our technical staff. In today’s world, our professionals are smart, curious, aggressive, and always looking for a team challenge. Global projects provide the opportunity to marshal resources from throughout the company and focus these strengths on a project in Asia, the Middle East, or anywhere in the world where our cli-ents are operating.

Whether this calls for rotating people in and out of the project site, or relocating them for a specific period of time, we’ve found that global assignments are highly sought after by our best people. They appreciate the opportunity to work together on a challenging project with a variety of team-mates in a new setting. What they take away from the expe-

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 engineer-ing 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 project happens to be located in Abu Dhabi or Macau doesn’t change the need to follow proven procedures. You will

need to adapt to local requirements, but the basic attention to quality standards should never vary.

Apply the latest proven technologyNotice I didn’t say to be on the “bleeding edge” of tech-

nology. That’s a recipe for disaster. But global projects do tend to test the limitations of communications. So you need to make sure your technology gurus evaluate each global opportunity. Technological tools can range from tablets and project management apps to cell phones and file transfer protocol (FTP) sites. Just keep in mind, one reason you’re being chosen to participate in the project undoubtedly is the reputation U.S. firms have for being on the leading edge.

The results can be incredibleIn the future when I retire from RJA, I hope that one of

my legacies at our company will be the pursuit of a global presence. It started when I joined the company in the early 1990s, and I can’t tell you how gratifying it is to talk with our consultants who have participated in landmark projects all over the world. Going global is not an easy journey, but it is a destination definitely worth the trip.

Martin (Mickey) Reiss is president and CEO of The RJA Group Inc., parent company of Rolf Jensen & Associates Inc. He is a member of the Consulting-Specifying Engi-neer editorial advisory board.

2 More Minutes

Meeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationMeeting the challenges of globalizationThis firm’s globalization process has come with many “lessons learned.”

BY MARTIN (MICKEY) REISS, PE,FSFPE

THE RJA GROUP INC.

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©2012 Lutron Electronics Co., Inc. | P/N 368-2856 REV B

For more information please visit www.lutron.com/esbor 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 thatutilize 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% reductionin 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.

Lutron systems help the Empire State Building achieve sustainability goals.

Lutron lighting controls and sensors save up to 65% of lighting energy.*

• Wireless – simplifi es installation and minimizes disruption• Flexible – for easy retrofi ts or new construction• Expandable – add to a system or reconfi gure at any time

Empire State Building sustainability goals

Building energy reduction 38%

Building carbon emission reduction(over the next 15 years)

105,000metric tons

Annual building energy bill reduction $4.4 mil

Lutron contributions toward overall goals

Projected lighting energy reduction 65%

Projected lighting controls installed payback 2.75 years**

“ 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 MalkinEmpire State Building Company

Learn about our other energy-saving projects at www.honestbuildings.com/lutron

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