Engineered Systems Magazine Mayo-2015

w w w . e s m a g a z i n e . c o m

I N S I D EI N S I D E

IAQ Hits Students Harder / pg 25

National Board Violation Report / pg 34

Designing Duct Distribution / pg 59

IAQ Hits Students Harder / pg 25

National Board Violation Report / pg 34

Designing Duct Distribution / pg 59

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4 Engineered Systems MAY 2015

ENGINEERED SYSTEMS (ISSN: Print 0891-9976 and Digital 2328-1006) is published 12 times annually, monthly, by BNP Media, Inc., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualifi ed individuals. Annual rate for subscriptions to non-qualifi ed individuals in the U.S.A.: $123.00 USD. Annual rate for subscriptions to non-qualifi ed individuals in Canada: $160.00 USD (includes GST & postage); all other coun-tries: $178.00 (intl mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2015, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at ad-ditional mailing offi ces.

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MAY 2O15INSIDE

DEPARTMENTS

34 The National Board Violation Tracking ReportIts one thing to have equipment found to be in violation of code. Its another thing to have an expensive and possibly fatal accident as a result of such operation. Avoid both of those things by noting the common mistakes regarding cutoffs and flow-sensing devices, and by engaging your inspector to make sure you are up on the latest mix of requirements for your jurisdiction and particular system.

By Chuck Withers

38 High School LEEDershipSpurred by student initiative, this Minnesota magnet school has become the host for a unique collaboration focused on auditing and improving its mechanical and environmental performance. See how the partnership has gotten off to a solid start in conducting what is far from your average extra credit assignment.

By Jeffrey Seewald, P.E., CEM, and Corinne Wichser, LEED AP BD+C, O+M

Advertiser Index . . . . . . . . . . . . . . 63Back2Basics . . . . . . . . . . . . . . . . . 10Building Automation . . . . . . . . . . 22Case In Point. . . . . . . . . . . . . . . . . 14Classifieds . . . . . . . . . . . . . . . . . . . 57Commissioning . . . . . . . . . . . . . . . 20Editors Note . . . . . . . . . . . . . . . . . . 8Glossary . . . . . . . . . . . . . . . . . . . . . 63IAQ: A Physician's View . . . . . . . . 25Issues & Events . . . . . . . . . . . . . . . 53Literature & Catalogs . . . . . . . . . 56Products in Focus . . . . . . . . . . . . . 55Software & Apps . . . . . . . . . . . . . 54The Facility Files . . . . . . . . . . . . . . 24Tomorrows Environment. . . . . . . .59

COVER STORY28 VRF With Heat Recovery Ventilation In PreK-12 SchoolsAs the learning curve for VRF continues, its only fitting to see how it can fare in a familiar learning environment. Turns out it can play a key role in the critical lesson of adapting to existing spaces and occupancy needs when crafting the optimum retrofit design for a given client.

By Robert G. Thompson, CDT, LEED AP

BOILERS

K-12 / ENERGY MANAGEMENT

43 Temporary HVAC: Work The PlanKeys include prioritizing what types and levels of HVAC service youll need, managing site and fuel choices, and finding the right vendor(s) to provide the necessary equipment. You might note that most of that is nearly impossible to do once the trouble actually arrives.

By Steven G. Liescheidt, P.E.

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Robert Cowan, P.E. Premier, Inc.

Timothy Coyle, P.E. Power Consulting & Training, Inc.

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Paul Ehrlich, P.E. Building Intelligence Group

Rebecca T. Ellis, P.E. Questions & Solutions Engineering

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Philip Leader, P.E. Albert Kahn Associates, Inc.

Evans J. Lizardos, P.E. Lizardos Engineering Associates, P.C.

Jack McGowan, CEM Energy Control, Inc.

Howard McKew, P.E., BuildingSmartSoftware.com

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We got some great news just before shipping this issue to the printer. Stephanie Tay-lor, MD, who is writing a

year-long IAQ column for us, has been invited to be a Fellow in the Royal Soci-ety for Public Health (www.rsph.org.uk). The RSPH describes its mission as work-ing to help inform policy and practice, working to educate, empower, and sup-port communities and individuals to live healthily. Out in the field, this takes the form of various projects including various conferences and accreditation opportunities, policy work, reports, and campaigns.

Stephanie informs us that she appar-ently came to the Societys attention via her February column in our pages, which discussed indoor humidity levels and the sometimes surprising consequences of not maintaining enough of it. When shes not writing columns (well, and even when she is), she is the CEO of Taylor Healthcare Commissioning in Stowe, VT. Our congratulations to her!

TODAY: TODAYS BOILERMay and November are Todays Boilermonths around here, so if you find one accompanying this issue, be sure to check it out. Todays Boiler is the magazine we produce for and with the help of the American Boiler Manufacturers Associa-tion (ABMA).

As usual, this edition of TB features tips and topics from a variety of knowl-edgeable ABMA member companies. Specifically, the spring roundup explores strategies for reducing emissions, cutting down on steam energy losses, achieving better turbine efficiency, and so forth. Short features on flame detection and the evolution of rental boilers also add interesting info.

However, the National Board has con-tributed an article about the report they generate to track the various violations they find in their boiler and pressure vessel inspections. It focuses on the main offenders and could help you avoid vio-lations or worse in your own facility. We thought it was important enough, in fact, that weve included it in both Todays Boiler and this months issue of ES to maximize its exposure.

Remember that you can also view the digital editions of the last few years of Todays Boiler anytime youd like at www.esmagazine.com/boiler. The articles hold up well over time and you get the bonus online convenience of various hyperlinks for your further investigation. Its handy.

IF THIS, THEN THATFinally, attentive readers will note thatwere incrementally adding little touches here and there to make the issue more useful. One example is the effort to inte-grate your print experience with the websites substantial archives. So at the end of a couple of feature articles this month, youll observe a box with some archived features that tie in nicely with the feature at hand.

I have hand-picked these links myself, and weve created custom, simpler URLs for them, so you dont need a photo-graphic memory to actually turn and use the URL to get to a recommended article online. Its a small thing, but hopefully it will help a few of you now or later when you could use it.

Now if youll excuse me, I need to go ask Dr. Taylor when we get to have tea with Her Majesty. ES

By Robert Beverly

Also, read about deficient boiler rooms to avoid danger in your own.

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At some point in time, most school building com-mittees are given the responsibility to establish a building program to expand their city or town school building assets. For this B2B test, we will be focused on a building committee adding new

kindergarten classrooms on to the existing building, allowing the school to reuse the old kindergarten space for a library for students. A Building Program (BP) is created and this document will be the cornerstone for investing in an HVAC design and eventual construction of HVAC systems to meet the Building Program requirements.

The HVAC engineer will take this program information and craft a Basis of Design (BofD) using the suggested BofD template on Page 2 of this B2B. For this months test, we have documented the BP for a new kindergarten building addition at the K-6 school in Watford City, ND. On page 2 of this B2B, the reader shall complete the BofD by checking the correct boxes from the multiple choice selections based on the BP information provided herein and from pertinent reference documents, such as local weather data design criteria for this city. The answers to the BofD can be downloaded on the www.esmagazine.com web site.

The new building addition will be a 3,000-sq-ft, one-story structure slab-on-grade. The building will require a special security system that will be integrated with the HVAC system for fire alarm, and it will include TV security cameras at stra-tegic locations. Utilities will be extended out from the existing 24,000sq-ft school building to provide electricity, gas, and city water to the new space.

Electrical, plumbing, fire protection, and security consultants will work in sync with the HVAC design team to provide a com-plete mechanical-electrical installation and shall be per state and local codes.

The HVAC electrical requirements shall be 120/1/60 for motors less than .5 hp and 480/3/60 for motors .5 hp and larger. An existing gas-fired 1,300 MBH condensing hot water boiler will provide hot water heating to the kindergartens radiant heat floor, central AHU, and four individual fan coil units. The HVAC central air systems shall be direct outside air systems with energy recovery from the dedicated addition exhaust system to provide ventilation to the four spaces that make up the new kindergarten addition. Each room shall be capable of automatically and/or manually being commanded to unoccupied mode along with a morning warm-up and morning cool-down sequences of opera-tion. A central AHU will have an enthalpy airside economizer, with direct expansion cooling and MERV 8 pre-filters and MERV

14 final filters. Fan motors shall include VFD fans to provide outdoor air ventilation to each fan coil unit during occupied cycle and morning cooldown.

The entire building addition will have its floor heated via radiant heat, with the associated fan coil units providing supple-mental heat and ventilation. There is no requirement for standby capacity and no system/equipment spare capacity for BP growth.

The HVAC design of this building addition shall be based on State and local codes, as well as the design engineer referring to the ASHRAE 2015 Application Handbook chapter 7 Educational Facilities for basis of design requirements. The design engineer will draw upon the ASHRAE Advanced Energy Design Guide for K-12 School Buildings for more specific energy conservation design opportunities. In addition, reference should be made to ASHRAE 2012 HVAC Systems and Equipment Handbook chapter 54 radiant heating and cooling; also draw upon ASHRAE 2015 Application Handbook and its Building Operation and Manage-ment chapters 36 through 43 for additional BofD.

The design engineer, in conjunction with the school building committee and the architect, will finalize the HVAC system to include a closed loop hot water heating system. There will be no air-conditioning requirements. The new central air system and its associated exhaust air system and energy recovery wheels are located on the roof. Fan coil units will be located out of the classroom space for servicing as well as to minimize noise to the occupied rooms.

The HVAC system could be designed for occupied-unoccu-pied modes of operation Monday through Friday, 7 a.m. to 4 p.m., with manual override if needed. Hot water heating system shall be a fixed 160F HWS and 130F HWR during the heating season and the existing boiler will be off when outdoor tem-peratures reach 60F. Occupied space shall be maintained at 70F with no humidity control in the heating season and no summer space temperature control requirements during the air-condi-tioning season. Equipment room and back-of-the-room support areas will be maintained at 60F with no humidity control in the heating season.

There will be a LEED Platinum certification requirement with other specialized energy/environmental program criteria based on ASHRAE recommended school guidelines. The reader is directed to the Facility Files for the Owners Building Program Annual Operating Budget and Operating Program.

As the design phase for this BP goes forward, the BofD should be routinely referenced and updated based on changes in the BP and on any changes and/or enhancements to the HVAC design.

2Back Basics By Howard McKew, P.E., C.P.E.

Building Program To Basis Of Design For A New Kindergarten Addition To An Existing K-6 School

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2Back Basics

To view the solution online, please visit www.esmagazine.com.

BASIS OF DESIGN NEW K-6 GRADE SCHOOL BUILDING PROJECT

Date: May2015 Project Name: New Kindergarten Addition in Watford City, North Dakota Project #: 2015-05 Prepared By: Reader Revision date:

BUILDING New Construction Renovation Addition Sq. Ft.: No. of floors below grade: No. of floors at and above grade:

UTILITIESElectrical: New Upgrade Existing Natural Gas: New Upgrade Existing Steam: New Upgrade Existing Chilled Water: New Upgrade Existing

Hot Water: New Upgrade Existing Services from Utility for: Electric Gas District energy steam Existing

Campus Power Plant: Electric Gas Steam CHWS CWS Hot Water None

UTILITY DESIGN PARAMETERSElectrical: 120/1/60 208/3/60 277/3/60 480/3/60 /3/60

Emergency Power: New Diesel oil Gas Existing None Gas: Design parameters by plumbing engineer

Steam Pressure: Low @ psig Medium @ psig High @ psig High @ psig

Chilled Water Temperature: CHWS @ 42F CHWR @ 56F None

Condenser Water Temperature: CWS @ 85F & CWR @ 95F None

Hot Water Temperature: HWS @ 160F & HWR @ 120F when 26F OAT Off above 60F Fixed HWS @ 160F & HWR @ 130F None

ASHRAE APPLICATION HANDBOOKASHRAE 2015 Handbook: Chapter [ ] ASHRAE 2012 Handbook: Chapter [ ] [ ] [ ]

OWNER MECHANICAL DESIGN PARAMETERS

Equipment Location: On floor being served In central equipment room(s) In penthouse On-Roof Above Ceiling Outside Occupied Space

Maintenance Outside Occupied Space: Yes serving primary HVAC equipment No

Redundancy: For Boiler N+1 N+N No

Equipment/System Expansion: Increase equipment size by 15% NoIndoor Air Quality at: MERV rating of [ ] for pre-filters MERV rating of [ ] for final filters

Acoustic & Vibration Criteria: Design parameters by acoustic consultant None

Specialty Room(s): (List Room) None

Occupancy Schedule: 24-7-365 Occupied/Unoccupied with Manual Over-Ride

DESIGN CRITERIAOutdoor Dry Bulb & Wet Bulb: F Heating season F/ F Cooling season

Occupied Space: Occupied 24-7 Period Occupied-Unoccupied Period Warm-Up & Cool Down Set Points: F heating season & F cooling season 60% RH

Mechanical & Electrical Space and Back of the House Area: Occupied period Unoccupied period Warm-up and cool down Set Points: F heating season & F cooling season 60% RH

ENERGY & ENVIRONMENT CRITERIALEED Certification: Yes No Other certification (List the program)

Annual Operating Budget: With energy budget With organization structure Outsource operation & maintenanceRefer To "The Facility Files" For Additional Operation & Maintenance Design Criteria

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CASE IN POINT

Community college takes advanced course in life safetyDelaware Technical and Community College offers educationalopportunities for the community, including career/general de-

velopment, transfer education, workforce training, and lifelong learning. With over 5,000 students attending the college, life safety is a priority for the 147-acre Owens

Campus in Georgetown, which spans 10 different buildings.In order to maintain a high standard of safety, the college de-

cided to install new fire alarm systems with emergency commu-nications (ECS) and mass notification (MNS) capabilities. Chief Bill Wood, the chief of public safety, was the main decision driver for Delaware Techs proposed ECS/MNS updates. At first, Wood only wanted to upgrade the fire alarm system by adding System Sensor horn strobes.

After attending a conference and hearing of Advantech Securi-tys reputation for campus life safety updates, Wood reached out to general manager Lee Thompson to replace the fire alarms in all university buildings. Advantech began upgrades in the five largest buildings by installing System Sensor strobes and speaker strobes.

Advantech is a top flight company and a breath of fresh air, and weve been very happy with the system. Its been fault-free. Its here and doing its thing. We were overjoyed to get a new one, says Wood.

The System Sensor SpectrAlert Advance SP series of strobes and speaker strobes worked well for this project because the de-vices offer one of the highest fidelity sound outputs in the market,

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When it came time to upgrade the fire alarms at Delaware Technical and Community College, the college decided to take safety a step further by choosing systems with speaker strobes, colored lenses for specific emergency events, and remote activation.

vis i t us at www.esmagazine.com and fol low us on 15

according to the company. The speakerstrobes transmit a clear, intelligible mes-sage and provide the necessary visible no-tification. System Sensor also offers a full line of colored lenses so the devices can also be customized based on a wide vari-ety of emergency events. The evacuation speakers are designed for quick installa-tion and top performance in noisy envi-ronments. The low total harmonic distor-tion of the SP series provides high-fidelity sound output, making them ideal for use in high-ambient noise environments such as universities and campuses.

System Sensor speaker strobes are easy to install, and the plug-in design is great. The quality is excellent, especially with canned messages, says Thompson.

In addition to heading the update ini-tiatives and fire alarm design of the strobe system, Wood determined that the ECS/MNS system should be upgraded with voice capability. However, after installing speakers in the common areas, it was dis-covered that the conference room doors muffled the sound when closed, and that the soft tone of the original voice mes-sage didnt register well from such a long distance. Advantech Security further cus-tomized the audibility for the colleges needs and improved the emergency mes-saging in order to solve the intelligibility problem by adding more devices.

We wanted to make the speakers loud, but not too loud so the message gets dis-torted, explains Thompson. So our so-lution was to add more speakers in areas where the message was quiet and increase the tap settings of certain speakers to 2W to ensure audibility. We also worked with the marketing team to create canned voice messages in the event of an emer-gency. Everything was clear.

Advantech Security also replaced an-nunciators with microphones and touch-screen remotes. Five buttons were pro-grammed for speaker strobes and one button for a page-all function. New wire was installed, horn strobes were replaced by speaker strobes, and 26 additional speaker strobes were added throughout the campus.

Due to the number of buildings in-volved, Advantech elected to use a Gamewell-FCI E3 panel. The E3 Series uses broadband technology as an added benefit, which allows complete system

integration over only two wires or fiber optic cables. Overall, 712 System Sensor devices were used over ten buildings. The intent is to adopt this fire alarm/emer-gency communication system model for the remaining Delaware Technical Com-munity College campuses.

Emergency communications and mass notification systems are more effective than a campus-wide page, especially in the event of an emergency, because of their clear messaging and advanced con-nectivity. Using the schools existing tele-phone system, Advantech used GW-FCI

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campus that would foster growth and development for its stu-dents. According to the district, they wanted a high school ca-pable of unlocking the hidden abilities of their students and one that would aid their teachers in preparing their students for the next chapter of their lives. Proper ventilation and building aes-thetics could accomplish this vision. The result is Cedar Ridge High School.

Cedar Ridge is a two-story, 375,000-sq-ft high school divided into four distinct academies: Academy of International Busi-ness and Economics; Academy of Professional Studies; Academy of Science, Technology, Engineering, and Mathematics; and the Academy of Visual and Performing Arts. Each academy houses its own media center, administration suites, and planning areas for teachers. The common areas for all students are the cafeteria, the athletic facility, and the outdoor courtyard which is considered the heart of campus and is home to several multipurpose events.

The design team and Round Rock ISD wanted this school be an environmentally-friendly facility. This LEED-certified

hool has several sustainable elements featured. It uses local limestone materials on the exterior of the buildings and offers an abundance of natural light. All the windows allow natural light

penetrate deep into the occupied spaces.The HVAC system featured in the high school also contrib-

ted toward it achieving LEED certification. Titus has several products installed that provide energy savings for the school.

veral areas in the new high school utilize displacement venti-tion, which is a unique alternative for air distribution.

The DVIR and DVBC are rectangular displacement diffus-ers. The DVIR is a unidirectional discharge diffuser designed for flush mount applications. The DVBC has a curved face and discharges air via a three-way pattern. Both units provide air dis-tribution by supplying large volumes of air at low velocities into the occupied zone. Easily adjustable air pattern controllers inside the units can create different airflow patterns in the space to op-timize occupant comfort. Some additional products featured in the school are the TMS diffuser and the TRM mounting frame.

The Titus TMSA is a steel diffuser that features adjustable vanes which vary the discharge pattern between vertical and

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CASE IN POINT

fire telephone modules AOM-TELF to connect the emergencysystem. Now, authorized users have the capability to dial in on the phone and activate the emergency system from any location.

When the alarm goes off, its audible and grabs your atten-tion so you listen to the message. In Delaware, you have to use an amber strobe if its a warning, and it can only flash white for fire. So developing canned messages allowed us to put a new sound in the fire alarm, Thompson says. Plus, we can control the sound level because you dont have to control the variability of some-ones actual voice. The campus also has an interconnected phone system, so we installed a Gamewell-FCI Telco device to connect the fire alarm input to the phone. Now a select few people can call the school and put in a password to talk through the phone and the speakers. Thats a good safety measure because an autho-rized individual could call and broadcast an emergency message no matter where they are.

Proper ventilation key toschools educational success

The Round Rock Independent School District (ISD) inRound Rock, TX, had a vision for a new sleek, modern

Cedar Ridge High School in Texas employed several air distri-bution tactics, including upgraded diffusers, on the way to LEED certification and a healthier learning environment for students.


horizontal for heating and cooling applications. These diffusersdeliver supply air in a 360-degree pattern and are designed to protect ceilings from smudging. All sizes have the cones provid-ing a uniform appearance. The TRM is an aluminum mounting frame used to make installation of grilles and diffusers and other ceiling components in plaster and sheet rock ceilings as simple as inserting them in a standard T-bar type ceiling. For typical ap-plications, the frame has adjustable fastening clips which adapt to a variety of plaster and sheet rock ceiling thicknesses.

According to Titus officials, numerous studies have been done on the importance of proper ventilation in schools, and Cedar Ridge High School has a state-of-the-art HVAC system that is providing superior performance that will contribute to the suc-cess of students and faculty.

Elementary school takescomfort control with VRF systemEnergy efficiency isnt just for commercial spaces and residentialhomes schools are also aiming to provide healthy and clean environments for children. However, high energy costs can be a significant drain on school resources. Sycamore Elementary School, located in Michigan, is just one example of schools start-ing to pay attention to energy efficiency.

Sycamore Elementary School looked to Vytau Virskus with Millennium Energy to help them replace their previously out-dated boiler system with a more effective and energy efficient HVAC system. The project needed a solution that not only had

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Sycamore Elementary School in Michigan employed a VRF heat pump system to not only reduce energy costs but also to provide greater zone control in classrooms.


low-energy consumption, but would also keep the children warmduring the chilly Michigan winters and cool during the summers.

After evaluating a variety of different options, Millennium En-ergy chose LG Electronics Multi V IV Air Cooled VRF Heat Pump system because of the quality and benefi ts it provided. Specifi cally, the Multi V IV is designed to meet the needs of a varying climate such as Michigan keeping students warm during the cold win-ters and cool during the summers, which can be very hot.

The Multi V IV system also allows teachers to heat or cool specific areas of the building simultaneously in an energy-effi-cient manner, which is a significant benefit over ducted systems. Sun-facing rooms can be kept cool while rooms that receive no sun can be warmer, providing students with a more comfortable learning environment. According to LG, its Multi V IV also offers users a more compact product that is lighter in weight than any other models currently on the market.

LGs Multi V IV systems are designed to provide a flexible so-lution with independent comfort zoning, which takes maximum advantage of LGs inverter technology. The system also has a minimal impact on the existing building, saving time and money during the installation. The design enables the VRF system to adapt to any current setup a building can offer and requires fewer materials than other systems.

For Sycamore Elementary, Virskus was able to integrate the HVAC system into the existing environment using the AC Smart

Premium control system provided with the LG package. LG Elec-tronics offi cials said they recognize that long-term effi ciency, com-fort, and reliability start with proper installation and services of the equipment; therefore, the company offered training sessions for Sycamore Elementary School personnel and service teams. The fi nal result will be an energy-effi cient HVAC system that is also extremely quiet a must for a classroom environment.

We were looking for a system that would not only cut costs, but also provide a quiet and functional classroom environment for the students, said Virskus, We were also able to connect the unit to a dashboard that will measure the energy effi ciency over time.

The system is gradually being installed in increments during school holiday breaks, while students are out of school.

The training sessions from LG were incredibly helpful, said Virskus. ES

CASE IN POINT

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By Rebecca T. Ellis, P.E.

Know Your Systems

COMMISSIONING

Some people consider commissioning to be too muchtrouble and too much time to tack on to the end of a project. Of course, commissioning is not something that should be tacked on to the end of construction, but it

is true that most functional performance testing necessarily occurs towards the end of construction. This does not mean, however, that the testing should be troublesome or extraordinarily time consuming.

The commissioning process throughout the design and construc-tion phases of a project is intended to minimize the level of effort and pain associated with testing during the acceptance phase. These early commissioning steps include design reviews, submittal reviews, con-trols integration meetings, and the development of customized func-tional performance test procedures and acceptance criteria reviewed by all responsible contractors. The intent is to go into the acceptance phase poised and prepared for smooth and successful testing.

Many hours of project team member preparation go into the pre-testing commissioning activities. This includes establishing a clear understanding of how systems are intended to function, agreeing on who is responsible for which parts of equipment and systems integra-tion, and, of course, the work required to install, start-up, and program the systems to perform as documented.

After all of this preparation, one of the biggest challenges we run into once functional performance testing begins is the introduction of new project team members who were not part of the pre-testing coordination or communication. Sometimes this is inevitable due to someone changing employment. However, it sometimes happens that new people are sent to the site to participate in testing because they are less costly per hour (i.e., less experienced) and/or less in demand than the people who had been an integral part of the systems coordination and planning process.

These new people may know how to manipulate their respective systems (e.g., HVAC controls, lighting controls, fire alarm, on-board equipment controllers, etc.) upon the request of the commissioning professional running the tests, but they do not know anything about the unique details of the systems being tested and cannot quickly answer questions about why the systems perform the way they do. When asked the why question, the best case is that these people can dig into the system programming and answer the question, but the time involved in arriving at an answer is excruciatingly long compared to simply asking the person who did the programming and/or setup work in the first place.

New people who are not familiar with the project history will dra-matically slow down the functional performance testing, increase the number of issues that need to be documented in the commissioning action list and followed-up on later, and result in excessive retesting time required before the systems can be accepted by the owner. All of these consequences of sending the wrong people to participate in

testing are the things that give commissioning a bad reputation. I am not implying that inexperienced test participants are the only potential source of these problems, but they will always be a contributing factor.

So, who are the best people to send to functional performance testing? I believe they are the following, depending on the systems being tested.

HVAC controls contractor - Whoever programmed the system Fire alarm contractor - Whoever programmed the system Mechanical contractor - Whoever started up the equipment with

on-board controllers Lighting controls - Whoever programmed the system and/or set up

the controllers Commissioning firm - The commissioning professional who was

most closely involved in the systems review, integration, and coordi-nation process

I believe that excellent pre-testing coordination, communication, and team follow-through, combined with having the best people par-ticipating in the functional performance testing, can cut the time spent on end-of-construction com-missioning activities (testing, issues resolution, and retesting) by 25-50%. ES

Ellis is president of Questions & Solutions Engineering Inc. (Chaska, MN). E-mail her at [email protected]

New people who are not familiar with the project history will dramatically slow down the functional performance testing, increase the number of issues requiring documentation in the commissioning action list and follow-up, and result in excessive retesting time required before the systems can be accepted by the owner.

WWW.ESMAGAZINE.COM/ELLISUse this handy shortcut to see Rebeccas entire online archive of commissioning insights.

Testing without the team members who can answer the why? of functional performance may be costly.

www.taco-hvac.com

Built in 1983, Tulsas 96,000 square-foot Remington Towers heating system had been updated with two new boilers, retaining its constant speed pumps. Given that the building was occupied for just 60 hours a week, part owner Mark Roberts searched for an automated solution to turn back the heating and cooling systems when the building was empty.

Energy surveyDuane Harmon, PE, of Crafton Tull performed the energy survey and suggested a control system retro t and the addition of variable frequency drives to the buildings pumps and chiller fan to reduce the buildings carbon footprint and o er a strong ROI.

The iWorX solutionHydronic Systems, Inc. of Oklahoma City recommended the iWorX remote building management and control system. They installed HPU2 modules on all 126 water-sourced heat pumps. Application-speci c modules were used on fan coil units, the chiller, boilers, pumps, lighting,

computer room alarms and outdoor temperature sensors. All modules were then connected to a web-enabled touch screen Local Control Interface. With plug-and-play iWorX modules, rst cost is last cost. Theres no propri-etary software involved and no programming required. Because iWorX software is web-enabled, its always up to date, too.

Quick paybackWith the variable frequency drives, iWorX controls, and a 40% reimbursement from the local utility, the actual payback was just three years. Whats more, the retro t cut the buildings operating costs by nearly 25% . To learn more about Taco variable speed solutions and iWorX, visit our web site or call to speak with a Taco engineer.

iWorX is a product of Taco Electronic Solutions, a subsidiary of Taco, Inc.

iWorX. Easy retro t, great payback.


By Paul Ehrlich, P.E.

Options and price points are converging to better serve a big slice of the commercial energy pie.

Building Automation For Small Commercial Buildings

BUILDING AUTOMATION

Generally, when we think about BAS or systemintegration projects, they are for larger projects such as schools, office buildings, and hospitals that are 50,000 sq ft or larger. These larger projects have

more complicated systems, higher energy usage, and can readily justify the investment in sophisticated controls.

However, according to the U.S. Energy Information Admin-istration, these larger buildings comprise only 6% of the U.S. commercial building stock. Even looking in terms of floor space, buildings less than 50,000 sq ft comprise 50% of the total floor-space, which means that they, in turn, use about half of the total energy consumed by all commercial buildings.

This raises a question about how we can provide connection and automation for these buildings beyond what is available using programmable thermostats. I see three distinct sets of solutions evolving for these smaller commercial buildings. Each has great potential and I expect that all three are going to con-tinue to evolve.

DOWNSIZED BASThe same controls that are used for larger commercial buildings can readily be used for smaller projects as well. In fact, this is a fairly common approach for owners such as school districts that want to use the same system to monitor larger and smaller schools. The only real challenge here is cost, but suppliers are starting to offer new options that make these large building sys-tems attractive even on smaller projects.

SMALL COMMERCIAL BASThere are a number of new products on the market that are specifically focused on small commercial building automation. Most of these start with a smart communicating thermostat (wired or wireless) that in turn connects to a central panel which can control additional loads, such as lighting. These systems are often focused on certain types of buildings such as retail or restaurants. These systems offer great potential at an attractive price point.

UPSIZED HOME AUTOMATIONIn reality, many small commercial buildings are not much larger (or more complicated) than a large residence. Home automation systems are finally starting to take off. Systems that provide for web-enabled automation of HVAC, lighting, and plug loads are now available at your local home center. Even more intriguing are some of the new solutions being sold by cable and phone compa-nies that offer security, HVAC, lighting, fire and water, and detec-

tion. The entrance of large technology companies into this space is anticipated to lead to rapid growth. It is a reasonable expectation that the same systems being designed for homeowners could easily be adapted for use in small commercial buildings.

The benefits to having automation in smaller buildings include the ability to better control energy usage, but also include monitoring, preventative maintenance, and enhanced grid integration. Look for these new systems as you embark on your next small commercial building project. ES

The same controls that are used for larger commercial buildings can readily be used for smaller projects as well. In fact, this is a fairly common approach for owners such as school districts that want to use the same system to monitor larger and smaller schools.

Paul has worked on a series of ASHRAE projects including BACnet committee and Guideline 13 Specifying DDC Controls. The formation of Building Intelligence Group allowed him to provide assistance to owners with the planning, design, and development of Intelligent Building Systems.

WWW.ESMAGAZINE.COM/EHRLICHUse this handy shortcut to see Pauls collected BAS wisdom in ES columns and other articles.

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THE FACILITY FILESBy Amanda Parolise

SALARIES, WAGES & BENEFITS

Employee salaries & wages (0) Manager (0) Supervisor (2) Custodians $ 40,000

Taxes, health care, etc. $ 16,000

Retirement & benefits $ 4,000

OUTSOURCE OPERATION & MAINTENANCE

Project management $ 0

Vendor salaries & wages $ 0

Supplies $ 0

SERVICE CONTRACTS

Refrigeration equipment None $ 0

Heating equipment (1) Condensing boiler twice a year $ 1,800

Filters By school maintenance $ 100

Emergency generator None $ 0

CONSULTANTS

CAD None $ 0

Energy None $ 0

Information technology None $ 0

INFORMATION TECHNOLOGY

CMMS None $ 0

Handheld devices None $ 0

EXPENSES

Education None $ 0

Conferences None $ 0

office supplies $50 per month $ 600

UTILITIES

Electricity $ 30,000

Gas $ 149,900

Oil $ 0

Propane $ 0

District/campus steam $ 0

District/campus chilled water $ 0

District/campus hot water $ 0

DOCUMENTATION

Printing $ 0

UTILITIES

Maintenance repair None $ 0

In-house HVAC modifications None $ 0

Capital projects None $ 0

Energy initiatives None $ 0

TOTAL ANNUAL OPERATING COST $242,400

TOTAL ANNUAL OPERATING COST/Sq Ft $8.98

Administrative

Parolise is project manager consultant with BuildingSmart Software LLC.Reach her at [email protected].

For a building program to be successful and sustainable, it must include an operating budget as well as a construction budget. Fifteen to 20% of the cost of a building is first cost, and 80% or more of the cost to own a building is in the operation of the building over its life. The following is a sample of what the HVAC annual operating budget add-on to a current K-6th grade operating budget could look like at the conceptual phase of a building addition project.

When designing a new or renovated school facility, the design engineer should refresh her memory relative to this Basis of Design by first going to ASHRAE Handbook 2015 Applications and read chapters 7 Educational Facilities, chapters 36 through 43 relative to building operation and management, chapter 54 radiant heating and cooling, chapter 59 HVAC security, and chapter 61 codes and standards. Also, a review of the LEED New Construction and Existing Building certifications should be done even if the owner chooses not to apply for the certification but rather to be LEED-compliant.

Quite often, city and town school departments will retain in-house building management and operation and maintenance for the day-to-day requirements, but will most likely contract major HVAC equipment maintenance to an HVAC service company for the planned maintenance of the seasonal primary equipment startup and shutdown. The conceptual design phase annual operating budget for the 3,000-sq-ft building addition noted below will be added into the entire operating budget with the other 24,000-sq-ft space as follows.

Building Program To Basis Of Design For A New Kindergarten Addition To An Existing K-6 Grade School


Stephanie Taylor, M.D., M. Arch, CIC

Why Do Students Sleep in Class?

IAQ: A PHYSICIANS VIEW

How many classes have you slept through? Formyself, this number is scary to contemplate. No matter how close I am to the front of the room, how important the subject is, or

how much I respect the teacher, I have fallen asleep in far too many classes! Why do students fight fatigue and inattention in classrooms?

Students can be tired for a myriad of reasons unrelated to school. Perhaps they stayed up too late the night before, have post-prandial fatigue, or are uninterested in the subject. But students also struggle with fatigue as well as respiratory illness because of poor IAQ in classrooms. There are approximately 55 million elementary and secondary students in schools in the U.S., as well as 7 million teachers and staff, so maintaining good IAQ is an essential responsibility.

Building-related illnesses in students and teachers have been linked to volatile chemicals used in cleaning agents, off-gassing from floors or carpets, outdated or undermaintained ventilation exhaust, and intake systems or old HVAC systems. Most studies on IAQ health effects have focused on air pollutants regulated under the Clean Air Act, such as CO, ozone, particulate matter, and NO2. However, other pollutants measured less routinely have also been associated with respiratory system inflammation and serious allergic reactions.

In addition to the sheer number of students in school buildings, childrens bodies are different from adults in many ways, making them especially vulnerable to problems from poor IAQ. The physi-ological characteristics of children make them more susceptible to indoor air tox-ins such as ozone, nitrogen oxides, par-ticulate matter, lead, mercury, molds, and volatile organic compounds. This results in higher internal doses of inhaled toxins in children compared to adults.

Some of the differences in the respira-

tory tracts of children include the following. Inhaled particles are absorbed and metabolized more quickly

and thoroughly because of higher metabolic rates.

When it comes to poor IAQ, children fare the worst.

FIGURE 1.

Continued on page 27

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Children have a higher pulse resulting inrapid absorption of inhaled toxins into their blood.

They have a higher minute ventilation rate per kilogram of body weight than do adults at rest.

Children tend to be more physically active than adults.

The lungs, immune systems, and brains of children are developing during a period that corresponds with the cell layer lining of the respiratory tract being particularly permeable to toxins.

Children have a larger lung surface area in relation to their body weight and breathe 50% more air per kilogram of body weight.

The period of early growth and develop-ment is a critical time when air toxins can have lasting effects on the future health of the child.

Children have longer lifespans, which gives them a higher risk of cancer from toxins they are exposed to at a young age.

Children are often mouth breathers so their nose cannot act as a filter for fibers or other particles.

A childs breathing zone is closer to the ground because they have a shorter stat-ure on average than adults, so they will breathe in more heavy chemicals such as mercury if they are present.

Inadequate classroom IAQ can also cause heightened physical stress simply during the mechanical process of mov-ing air into and out of a childs lungs. These stresses can interfere dramatically with attention and learning. For exam-ple, small changes in the airway radius increase the resistance to airflow to the

fourth power as shown by the resistance to flow equation:

Resistance ~ length / radius4

When inflammation of the respira-tory tubes occurs, much more work is created for respiratory muscles, muscles that already have significant oxygen and metabolite requirements in children. In pediatric patients, the work of breathing can account for up to 40% of the cardiac output, particularly in stressed condi-tions.

We need to protect all people using buildings, but youngsters in particular. School is mandated up to a certain age, childrens voices do not have the same authority as adults, and complaints of student fatigue may not be taken seri-ously. How can we improve this situation for students?

OUR SCHOOLS SHOULD GET IAQ REPORT CARDS!Make IAQ an essential consideration for school facility management with the fol-lowing yearly requirements. i. An on-site certified IAQ coordinatorii. A walkthrough evaluation on all school

district buildingsiii. The evaluation of classrooms, ventila-

tion systems, and maintenance opera-tions using checklists

iv. A written set of policies and schedules that describes ways to correct the iden-tified IAQ problems, prevent future problems, and respond to emergencies and concerns

v. An annual review of the plan requiring school board oversight and approval. ES

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IAQ: A PHYSICIANS VIEW

Dr. Taylor, a graduate of Harvard Medical School (MD) and Nor-wich University (Masters Architecture), is the CEO of Taylor Healthcare Commissioning, Inc. (www.taylorcx.com). She now focuses her lifelong commitment to promoting health on improving the safety of the built environment. She has numerous publications in Nature, Science, and other peer-reviewed journals.

WWW.ESMAGAZINE.COM/TAYLORUse this handy shortcut to see Stephanies entire online archive of IAQ insights.


The advent of small-capacity, variable speed refriger-ant compressors provide opportunities to design and install highly-efficient, controllable HVAC sys-tems making variable refrigerant flow (VRF) systems more commonplace within the industry. While they began with focused attention to the office and light commercial market, VRF systems can be applied to the institutional market.

Originally developed in Europe, these systems are designed for efficient power consumption, flexibility, a high level of zone control, and options for simultaneous heating and cooling. These features are very appealing to the education market, offer-ing school districts an alternative to conventional all-air hydron-ic systems normally employed in colder climates. Although somewhat more complicated than conventional air handling/unit ventilator systems, VRF systems offer solutions that can meet some rather unique requirements.

THE CHALLENGECannonDesign recently completed a major renovation and class-room addition at a 60-year-old school building that housed 500 students in kindergarten through sixth grade. This one-story

school was the center of the community and, with low-slung sloped roofs, it blended in to the neighborhood. With a distinc-tive design, the school offered a warm and friendly atmosphere for this developing population yet some students were located in temporary classrooms when capacity outgrew the exist-ing building. The district realized it was time to renovate the building while providing additional spaces for the anticipated 550 student population in appropriately sized classrooms. The renovated facility now includes a swimming pool, conventional classrooms, a science/technology/engineering/math (STEM) specialty classroom, kitchen, cafeteria, and upgraded staff and teacher support spaces.

With an active setting filled with afterschool and evening activities, the facility needed to provide an improved indoor environment. The existing heating- and ventilating-only system was beyond its remaining useful life. To complicate the con-struction phase, the school had to be fully operational during the entire project, so well-planned phasing was critical without adversely affecting the schools operation.

The selection of a VRF HVAC system with heat-recovery ven-tilation was based on three major factors.

As the learning curve for VRF continues, its only fitting to see how it can fare in a familiar learning environment. Turns out it can play a key role in the critical lesson of adapting to existing spaces and occupancy needs when crafting the optimum retrofit design for a given client.

By Robert G. Thompson, CDT, LEED AP


Physical constraints to house HVAC equipment within the building Phasing requirements Simultaneous heating and cooling requirements

The school district required a high degree of space flexibility to accommo-date its diverse activities, with requests for simultaneous heating and cooling year-round. Summer programs includ-ed educational and community events, so air conditioning was highly desirable. Because of the building configuration and exterior exposures, summer/winter changeovers would be problematic. Also, there was little opportunity to conceal ductwork above ceilings in the existing, low-profile building, except in the new addition. Roof-mounted equipment on the existing sloped roof was not feasible without adversely altering the buildings street-level appearance.

Space for HVAC equipment within the existing building was also at a premium. Two basement-level mechanical rooms housed gas-fired furnaces for heating and ventilation. All existing ductwork was installed within limited access crawl spaces. No space was available at grade.

There were four main construction phases for this project. Each of the four phases required removal of existing systems and completion of new systems so each building portion could be occupied and meet safety and thermal conditions including ventilation.

In consideration of the buildings architectural appearance and an effort to maintain a clean look, all exterior HVAC equip-ment needed to be strategically located. The roof addition was designed to accommodate new HVAC equipment to its maxi-mum potential.

THE SOLUTIONThe challenge was met by installing multiple VRF systems pro-viding heating and cooling, while utilizing the existing basement mechanical spaces to house ventilation equipment. Classrooms required 15 cubic ft per minute, per person, of ventilation air, with individual controls for both heating and cooling. Other spaces such as the cafeteria, library, and gymnasium/auditorium also required individual controls. In all, seven separate VRF systems were installed along with three air handling ventilation systems with heat recovery capability. This configuration of separate systems accommodated the phased renovation. Multiple VRF systems were selected for various building wings.

The indoor units consist of one- to four-ton nominal indoor units, with some conventional wall-mounted and console units serving offices, cafeteria, hallways, and adjacent spaces. The classrooms are conditioned by either three- or four-ton hori-zontal indoor units, depending on the classroom size. Systems within the existing building are concealed and located in soffits,

FIGURE 1. Classroom soffit with concealed heat pumps. (Figure courtesy of CannonDesign.)

FIGURE 2. Hallways with indoor console units. (Figure courtesy of CannonDesign.)


built to mimic the original construction and complement thepartly sloped ceiling following the roof line. The new classrooms accommodate the indoor units above the ceiling. Other build-ing spaces contain either wall-mounted or console indoor units strategically located to provide heating and cooling.

In all cases, refrigerant piping is either concealed within ceiling spaces or in the buildings crawl space. As each indoor unit is piped with two lines, careful planning of the piping con-figuration and routing were required with piping installed in groups on common supports. The crawl space was utilized as much as possible, since it lies beneath the entire building and provides an advantageous locale for the piping arrangement required from the outdoor to indoor units. Corridor ceiling spaces in the existing building conceal piping serving the soffit-located indoor units.

VENTILATION Ventilation is introduced to all spaces in various ways. The exist-ing classrooms were previously heated by a hot-air system with supply air delivered through outlets integrated in outside wall bookshelves. The ductwork, located in a crawl space, was cleaned and resealed. It was then reutilized as the return-air path back to the heat recovery ventilation units. The new return-air grills are also integrated in to replacement bookshelves. The end results

are completely renovated classrooms with similar appearances to existing conditions.

Conditioned air is delivered to the inlet of indoor units then mixed with air heated or cooled then delivered at the appro-priate temperature. Corridor ceiling space below the sloped, peaked roof was just enough to accommodate the supply air ductwork.

Other spaces (offices, cafeteria, hallways, gymnasium/audito-rium) receive ventilated air directly from the ventilation equip-ment located in the basement mechanical room through new or existing ductwork. This neutral air is also returned to the ventilation equipment through ductwork in crawl spaces. Vari-ous indoor units also condition these spaces by recirculating the air within the space, and they can either heat or cool in the same manner as the classrooms.

RESPONDING TO THE CHALLENGEVRF systems can offer a good option in PreK-12 settings. This experience demonstrates that when heating and cooling loads are matched up to indoor unit capacities, heating and cooling capa-bilities can take place through the refrigerant in relatively small piping rather than ductwork. Ventilation requirements can be accommodated by separate dedicated systems. In this scenario, pre-heated ventilation air, by heat wheels in the ventilation units, is further heated in hot water reheat coils. The hydronic system

VRF with Heat Recovery Ventilation In PreK-12 Schools

FIGURE 3. VRF with heat recovery ventilation system diagram. (Figure courtesy of CannonDesign.)


is also sized to provide enough heating in the event of a power failure where the VRF system would not be operable. The con-cept of distributing heating and cooling through piped hydronic systems are very conventional. VRF functions in much the same way, but the refrigerant distributes the heating and cooling rather than water.

The total installed cooling capacity for this system is nomi-nally 140 tons, equivalent to 400 sq ft/ton. With the combined heating capacities of VRF equipment and hot water boiler heat-ing system, the heating capability matches the schools needs and both heating sources operate in tandem.

From the clients point of view, the equipment locations do not pose a maintenance issue as the indoor units are accessible and the outdoor units are either at-grade or on the new roof addition. The existing roof is kept clear, and the buildings exte-rior appearance is virtually unchanged.

SUMMARYThe challenges that existed at the projects beginning were met as follows. Simultaneous heating and cooling. VRF systems have this

option. Close attention to the heating capacities in northern climates is of utmost importance. In the heating/cooling mode, energy is essentially transferred from space to space by the

refrigerant before compressor operation is required. Limited ceiling space. The VRF indoor units are relatively

small and essentially consist of a fan coil unit with a refrig-erant coil that acts as either an evaporator (cooling mode) or a condenser (heating mode). They can be installed above limited clearance ceilings or exposed in the space as wall mounted or console units.

Exterior appearance. The outdoor units house the outdoor coil that operates as either an evaporator (heating mode) or condenser (cooling mode). They are relatively small in size and can be piped in parallel to provide the system capacity required.

Phased installation. Seven separate systems are installed to accommodate the phasing requirements, but also important was the relationship between the spaces to be conditioned to the location of the outdoor units.

Diverse school functions. Based on what activities take place within the building, the temperature control system can set up or set back temperatures of the separate systems. This feature can accommodate the use of parts of the building without con-ditioning the entire facility. The energy efficiency of the simul-taneous heating and cooling in heat recovery mode is enhanced by the simple fact that zones in the building that are not being used can be conditioned appropriately while spaces in use are conditioned based on need.

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LESSONS LEARNED VRF systems that include multiple indoor units in a system

require critical layout and sizing of the refrigerant piping. Equivalent pipe lengths need to be kept within the system capa-bilities. Each indoor unit is connected with two dedicated lines that are then connected to the refrigerant branch selector box. Manufacturers requirements need to be followed.

Location of outdoor units in regard to distance from the refrig-erant distribution boxes is also critical. Again, the manufac-turers requirements need to be followed.

Space for the branch selector boxes is required, and they need to be accessible for maintenance. The location of this equipment should be determined during the design.

Each indoor unit acts as a cooling unit, and thus the condensate that forms needs to be drained away. It is very important that the drain piping is sloped and sized adequately.

Refrigerant piping is extensive in multiple indoor unit systems and requires space, especially where multiple indoor units are served in close proximity. Though the individual lines serv-ing each unit are relatively small, with insulation and support attachments, the space needs can be more than expected.

Overall, the VRF system with heat recovery ventilation and a small hydronic supplemental heating system met the needs of the building HVAC requirements, allowing installation in conjunction with a phased construction/renovation so students, staff, and teachers continued their important work with limited disruptions. ES

Robert G. Thompson, CDT, LEED AP is withCannonDesign. His experience spans more than three decades, and as such, he is knowledgeable with the various mechanical engineering system requirements in health-care facilities, educational institutions and commercial buildings, as well as project man-agement. His K-12 experience includes both new construction and renovation/addition projects.

VRF with Heat RecoveryVentilation In PreK-12 Schools

If you liked this article, here are some others that might be useful. VRF And Building Codes by Marcia Karrwww.esmagazine.com/VRFcodes

Controls For VRF Systems by Paul Ehrlichwww.esmagazine.com/VRFcontrols

VRF Is Evolving by Marcia Karrwww.esmagazine.com/VRFevolving


Each year, The National Board of Boiler and Pres-sure Vessel Inspectors issues an annual Report of Violation Findings that identifies specific viola-tions commonly found on five types of pressure equipment during jurisdiction-required inspec-tions: high-pressure/high-temperature boilers; hot water heating/supply boilers; low-pressure steam boilers; potable water heaters; and pressure vessels.

For each type of pressure equipment, the report details specif-ic safety violations found on installed safety devices. Mandated codes and jurisdictional requirements identify which safety devices are required to be installed for each pressure equipment type. These devices include: safety relief devices; low-water cutoffs/flow sensing devices; pressure controls; temperature controls; burner management controls; level indicators such as gage glasses, bulls-eyes, and fiber opticals; pressure/temperature indicators; and other pressure-retaining items associated with the proper operation of pressure equipment (piping, pumps, valves, expansion tanks, etc.).

The Violations Tracking Report exposes key problem areas to provide the pressure equipment industry with categorical statis-tics that can be analyzed and used to focus attention on instal-lation, inspection, and maintenance of specific safety concerns.

2013 VIOLATION REPORT FOCUS: LOW-WATER CUTOFFS/FLOW-SENSING DEVICESLow-water cutoffs/flow-sensing devices are basic safety devices that will shut down and protect a boiler from failure due to low-water conditions or loss of flow. These protective devices are required by jurisdictional laws or regulations and are specified in jurisdictionally-mandated codes and standards for each of the following types of boilers: high-pressure/high-temperature boilers; low-pressure steam boilers; and hot water heating/sup-ply boilers.

For the three types of boilers noted above, there were 3,104 total violations for low-water cutoffs/flow-sensing devices iden-tified by jurisdictions within the 2013 reporting period. This article will focus on three key areas that had a combined total of 2,850 violations out of 3,104 noted, and which totaled 92% of violations: inoperative devices, missing or uninstalled devices, and installed devices with no manual resets.

Low-water fuel cutoffs and flow-sensing devices are relatively simple in design and manufacture; therefore, design or manu-facturing defects rarely contribute to failure. However, these devices are either mechanical or electronic and do require basic maintenance and testing to function properly and ensure safe operation.

Its one thing to have equipment found to be in violation of code. Its another thing to have an expensive and possibly fatal accident as a result of such operation. Avoid both of those things by noting the common mistakes regarding cutoffs and flow-sensing devices, and by engaging your inspector to make sure you are up on the latest mix of requirements for your jurisdiction and particular system.

By Chuck Withers


INOPERABLE: A HARD-LAYER LESSONThe following true experience illustrates the importance of regu-lar maintenance and testing.

A low-pressure steam boiler operating in a business for over 20 years was recently inspected by a qualified boiler inspector. That boiler inspector had repeatedly inspected the boiler from the time of installation. Within three months of the annual required internal inspection, the boiler overheated and cata-strophically failed, causing hundreds of thousands of dollars in property damage, not including loss of business revenue (there was a happy ending, though: no fatalities!). The cause of the failure: the business was sold right after the inspection was per-formed, and the original owner explained to the new owner the required maintenance needed for the boiler, including addition of chemicals, but the new owner continued to add chemicals without performing any required blowdowns of the boiler and

low-water cutoff. When the float-type and probe-type low-water cutoffs were

found, disassembled, and inspected, both the float chamber and probe were completely covered with a hard layer of chemical deposits, rendering both devices inoperative. The connecting 1-in piping for the float type low-water cutoff was completely filled solid with chemical deposit. The boiler operated for 20 years without any problems. If the new owner had understood the importance of continual maintenance, this incident easily would have been avoided.

Since there is no manmade device which is maintenance-free, performing proper maintenance is extremely important for safety. Although maintenance is important, testing is equally important. It is recommended that low-water fuel cutoffs be tested weekly while in operation by performing either an evapo-ration test or a slow drain test.

MISSING OR UNINSTALLED DEVICESMissing or uninstalled devices are violations that should not occur if laws, regulations, codes, standards, and even man-ufacturers recommendations are reviewed, understood, and observed. Laws and regulations specified by jurisdictions are specific to the type of boiler and provide clear direction for installing low-water cutoffs and flow-sensing devices. These laws and regulations do provide the requirements for installation of these devices, but in doing so, they may refer to other codes or standards such as the National Board Inspection Code (NBIC); American Society of Mechanical Engineers (ASME) Section I, Power Boilers and Section IV, Heating Boilers; ASME CSD-1, Con-trols and Safety Devices for Automatically Fired Boilers; Interna-tional Mechanical, Plumbing or Fuel Gas codes; as well as some fire codes and electrical codes. It is imperative that owners/users, installers, and contractors read and understand these referenced codes and standards.

Although these codes and standards strive to harmonize requirements, there are differences. The first step before any boil-er installation is to find out what the jurisdiction (where the item is to be installed) requires for each type of boiler. Remember jurisdictions are responsible for enforcing laws and regulations for public safety. Once jurisdictional requirements are known, questions such as how many, what type, when, where, and how to install low-water cutoffs and flow-sensing devices can easily be answered. Inspectors and jurisdictions should always be ready to offer guidance to those asking. Violations can be minimized if referenced standards and manufacturers recommendations are understood and followed.

MANUAL RESETSFor example, manual resets are not always required to be

installed on low-water cutoffs and are governed by jurisdictional requirements or the referencing standards specified in the juris-dictional laws and regulations. Manual reset on controls adds an extra layer of safety to ensure the operator verifies the low-water condition of the boiler and the cause of the boiler shutdown before manually resetting the control and restarting the boiler. As of fall 2014, 32 states, five Canadian Provinces, and Puerto Rico mandated in some part ASME CSD-1. Additionally, the Interna-

FIGURE 1. Float-type low-water cutoff.


tional Mechanical Code by reference adopts ASME CSD-1. Cur-rently, the International Mechanical Code has been adopted into state or local codes in 46 states, the District of Columbia, Guam, and the U.S. Virgin Islands.

To reinforce this need to understand differences between standards, let us look at the requirements for just one type of boiler low-pressure steam boilers. ASME CSD-1 requires two low-water cutoffs. The lower-set cutoff must cause a safety shut-down and lockout. A manual reset may be incorporated in the low-water cutoff or be installed separately. The required manual reset device may be the instantaneous type or may include a time delay of not more than three minutes. The NBIC, Part 1, also requires two low-water cutoffs with the second requiring a manual reset. ASME Section IV requires only one low-water fuel cutoff and does not require a manual reset or a safety shutdown or lockout. Again, this is just for one type of boiler.

There are many other types, such as modular steam or hot water, hot water heating/supply, high-pressure steam, high-temperature, electric, or miniature boilers. All these various boilers have different requirements for installation and opera-tion of low-water cutoffs. Without a detailed understanding of jurisdictionally-mandated standards, it is no wonder that we find so many violations when performing boiler inspections.

For forced circulation-type boilers wit

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