Organization: MCAA

CFI Mechanical Overcomes Skilled Labor Shortages with Victaulic Products and Services

Building information modeling (BIM) and 3D modeling offered by Victaulic’s Construction Piping Services (CPS) division helped CFI Mechanical manage the lack of detailers available in Houston, where construction is booming. Victaulic’s grooved piping systems and prefabrication services also saved CFI Mechanical installation time and money on a new office building project.

Building Boom Spurs Labor Shortage

Houston, TX, the heart of the oil and gas industry, has seen rapid growth in recent years, fueled by tax incentives for companies setting up headquarters in the area. The influx has led to a high demand for office space and, in turn, a wave of construction that has resulted in labor shortages. Despite the recent oil industry downturn, building activities continue at a breakneck pace. When they were awarded the mechanical systems contract for the Millennium II Tower, CFI Mechanical turned to Victaulic for help in overcoming the labor shortage, as well as schedule and budget challenges.

“CPS did exactly what they said they were going to do and when. … We can’t wait to get another job where we can plug in Victaulic.”

—Chuck Fell, President, CFI Mechanical

The Millennium II Tower is an office building under construction in the Westchase district of Houston. The long-planned sibling property to the Millennium Tower, Millennium II is a 24-story glass-and-aluminumclad tower that will stand 309’ tall, making it the tallest building in the district. All 417,000 square feet of space was pre-leased by National Oilwell Varco (NOV), a leader in the design and manufacture of oil and gas drilling equipment and Houston’s largest energy employer. With more than 14,000 employees in the area, NOV will consolidate employees from 10 other facilities at the Millennium II Tower when it is completed in October 2015.

Victaulic triple-service valve assemblies, strainers, couplings, and fittings join condenser water piping to pumps in the basement mechanical room of the Millennium II office building. Combining Victaulic products and CPS for BIM, CFI Mechanical saved installation time and overcame Houston’s skilled labor shortage.

“Construction has a lot of cycles to it, but for the last two years, it has been crazy around here,” said Chuck Fell, president of CFI Mechanical and immediate past president of MCAA. The Houston-based contractor, which provides plumbing and HVAC services for commercial construction throughout Texas, knew the labor shortages would present challenges on the Millennium II Tower project in terms of design and construction. In addition to welders, the company has experienced a shortage of detailers that has been magnified by mandates for BIM on projects. “There’s a lot more demand now on our drafting services,” Fell explained. “More customers want the Cadillac, they want everything.”

CFI Mechanical is also facing thetypical construction challenges ofschedule and budget. “We are buildingat a record pace around hereas far as the speed at which we putbuildings together,” Fell noted, “andbudget’s always an issue.”

Victaulic Services Extend Drawing Departments

Although CFI Mechanical planned to manage the BIM process in-house, it quickly became clear that help was needed. CFI Mechanical had not previously worked with the Victaulic CPS team, but the Millennium II Tower was a good project to test the waters. “We see a need for [CPS services] in the future, and this looked liked it was a good fit for Victaulic to come in,” Fell said.

Shortly after CFI Mechanical was awarded the contract, in January 2014, the contractor brought in the Victaulic CPS team to model the mechanical rooms and piping systems. The CPS team completed the fully coordinated BIM model for the basement and penthouse mechanical rooms, an air-handling unit room on the eighth floor, the cooling tower area in the attached parking garage, and the crossover piping, managing to stay ahead of the construction coordination timeline despite the tight schedule. CPS also generated isometrics, fabrication spool drawings, and bills of material, enabling the contractor to get a head start on fabrication.

Victaulic Products Speed Installation With years of experience working with Victaulic products, CFI Mechanical knew grooved piping systems would be the solution to the schedule and budget challenges, as well as the labor shortage. “We’ve been in business for 19 years; we’ve used Victaulic for 19 years,” Fell stated. “We try to use it every possible way.”

In 2014, CFI Mechanical executives toured Victaulic headquarters in Easton, PA, where they got a closer look at the manufacturing and quality control processes. Already a proponent of Victaulic because “there’s a trust factor there,” according to Fell, the tour gave CFI Mechanical’s leadership even more confidence in the products. It also revealed new ways to improve efficiency. “It changed our approach, got us more into fabricating and using the tools available to us from Victaulic,” said Fell.

Victaulic grooved mechanical piping products, including QuickVic™ Installation-Ready™ couplings and AGS couplings, were specified to join the carbon steel condenser and chilled water piping systems as well as the stainless steel and copper domestic water systems. In addition to the mechanical systems, Victaulic products were specified for the storm drainage and fire protection systems.

“We could not have accomplished our budget for the job without using Victaulic products, and it would have been a whole lot more difficult keeping up with the schedule.”

—Chuck Fell, President, CFI Mechanical

The Victaulic CPS team coordinated bag-and-tag product shipments to CFI Mechanical’s fabrication shop. This service enables Victaulic products to be shipped to the shop or jobsite for just-in-time delivery, labeled and packaged per the contractor’s direction. Pipe spools were cut, grooved, and assembled in CFI Mechanical’s shop and sent to the jobsite for installation.

Cooperation Keeps Project On Time, On Budget

The installation went smoothly, and the CPS team stayed involved throughout the construction process, assisting with several design changes. For instance, an extra floor was added, which increased the size of the piping at the lower levels and called for larger cooling towers. The control valves that had been ordered per the contract drawings did not fit the cooling tower connections, and the lead time to get new valves would have delayed construction. The CPS team devised a solution using Victaulic reducers, which enabled the original control valves to be used and construction to progress on time.

The Millennium II Tower project is on time and on budget. “We could not have accomplished our budget for the job without using Victaulic products,” Fell stated, “and it would have been a whole lot more difficult keeping up with the schedule.” Despite CFI Mechanical’s reservations about working with CPS, attitudes changed by the end of the project. Initially concerned about costs, prompt service, and lack of control, Fell reported that the project “turned out very well. CPS did exactly what they said they were going to do and when. The value was there. We can’t wait to get another job where we can plug in Victaulic.”

For more information, visit www.victaulic.com.

The Warko Group Strikes Perfect Humidity Balance with Rawal Devices

Pharmaceutical specialty and medical device manufacturer Angiotech had tried almost everything to keep humidity levels in its cleanrooms just right, but only the APR Control from Rawal Devices, Inc. was up to the task. Since The Warko Group installed the device, Angiotech has maintained humidity and temperature in its cleanrooms well within required specifications.

Too Damp or Too Dry

Before installing the APR Control, John Garbini, facility support manager for Angiotech, had been stuck with a nagging problem: When the humidity in the plant’s ISO Class-8 cleanrooms was not too high, it was too low. He had tried dehumidifiers. He had tried a large industrial desiccant unit. Balanced dampers? Reduced air pressure? Been there, done that. Angiotech uses its Reading, PA, plant to assemble and package sterile, disposable scalpels and surgical needles with attached sutures. High humidity in the cleanrooms could not only encourage bacterial growth, it could prematurely degrade a type of moisture-activated suture that is designed to slowly dissolve in human flesh after the surgical incision heals. Low humidity, on the other hand, promotes static electricity, which interferes with computerized packaging and labeling equipment and gives employees small shocks.

“Temperature and humidity swings were normal,” Garbini recalled.“Our employees were either too hot or too cold. It was a challenge to maintain the proper temperature while still dehumidifying the space.The air-handling compressors were constantly slamming on and off, but the main problem was that I could never get the humidity low enough to stay within our specs, which are more stringent than the federal cleanroom standards.”

The APR Control from Rawal Devices “made such a significant impact that we installed another one in the air handler for the other cleanroom.”

—John Garbini, Facility Support Manager, Angiotech

Bob Reichenbach, service manager for The Warko Group, had been recommending the APR Control device for years, but Garbini had not found room for one in his budget. Finally, he purchased the device along with a new air handler for the troublesome cleanroom (the one where the needles with moisture-activated sutures are packaged). It was installed in late December, when the plant was shut down for the holidays. At last, Garbini was able to keep the room at 20–50-percent relative humidity regardless of the weather outdoors. (He calls the device “Little Pauly” after Paul Gardner, the amiable Warko Group mechanic who installed it.)

Temperature, Humidity Stabilized

The APR Control smoothly modulates a direct-expansion air conditioning system’s capacity,allowing it to dehumidify the space without overcooling it. The device varies refrigerant flow according to suction pressure, which changes with the temperature of air crossing the evaporator coil. Because it continuously monitors the heat content of return air, it maintains the system in a dehumidifying mode more efficiently than thermostats and humidistats and without risk of coil icing, liquid slugging, or excessive compressor cycling.

“The APR Control is running great, with no problems at all,” said Garbini. “It made such a significant impact that we installed another one in the air handler for the other cleanroom in May.”

Garbini continued, “We’re now maintaining humidity and temperature in both rooms well within specs, our employees are more comfortable, and I’ve even seen a decline in the electrical energy consumption.”

To allay any doubts that the improvements from the first installation could be attributed to the device (rather than the brand new air handler) and to demonstrate its effectiveness, Reichenbach persuaded Rawal Devices President Richard Rawal to donate the second unit. The results were enough to finally convince Angiotech’s upper management. Garbini recently ordered a third device for the finishing department, where the needles and blades are polished, cleaned, and washed before going to the cleanrooms for assembly and packaging. Though not an official cleanroom, this area requires frequent air changes, HEPA filtration, and, of course, stable levels of temperature and humidity.

Device Tracks with Load

A typical HVAC system is designed for a sunny 95º day with 95-percent relative humidity. On cooler days, because the system has more capacity than it needs to satisfy the actual load, it tends to cycle on and off. When it shuts off, the humidity increases, causing the room’s occupants to feel uncomfortable even when the temperature is within the desired range. Occupants tinkering with the thermostat only make things worse.

The device improves an HVAC system designed for on/off operation by allowing it to “track” the load—that is, to operate at the same capacity as the load. In other words, a compressor pumps only what it is rated for, but the APR Control “de-rates” the evaporator coil for a reduced load.

Reduced compressor cycling means energy savings and less wear and tear on the compressor.

In a system equipped with the APR Control, even if a filter is clogged or a belt malfunctions, coil temperature never falls below freezing. With no coil icing, the building is spared the water damage often caused by melting coil ice. The device is also used for high-percentage (up to 100 percent) makeup air systems, reducing the cycling caused by wide variations in the temperature and humidity of outside air.

For more information, call 800-727-6447 or visit www.rawal.com.

Bassett Mechanical Streamlines Payment, Reporting Processes with Viewpoint Software

By replacing their outdated accounting and management software with easy-to-use, flexible Vista™ by Viewpoint, Bassett Mechanical has improved efficiency and streamlined billing processes. “It’s important for our financial health that we get paid quickly, and by using the software, Bassett can give customers the documents they need (invoices, reports, etc.) the way they want to see them,” said Mike Kees, manufacturing project manager at Bassett Mechanical. “That means Bassett is presenting accurate data in a professional format with the right details per customers’ request, and so billing, for example, can be processed efficiently and not returned with concerns and questions that slow down the payment and cash flow.”

Bassett Mechanical provides custom-built mechanical contracting, metals manufacturing, and maintenance service solutions to customers throughout the United States and the world. Established in 1936, the company has grown into a trusted specialty contractor that handles design, engineering, fabrication, installation, and service in specialty areas including industrial refrigeration, HVAC, industrial ventilation, metal fabrication, plumbing and piping, laser cutting, testing and balancing, and preventive maintenance. In addition to its 266,000-squarefoot facility and fabrication plant in Kaukauna, WI, Bassett houses service locations in both Madison and Milwaukee.

“I was not very familiar with construction technology, but using Vista has been easy. … I can run reports myself and see exactly what I need to when I need to.”

—Roy Immel, Project Manager, Construction, Bassett Mechanical

Bassett Mechanical is continually growing and innovating to better serve their customers and support their Lean principles and processes. Having outgrown their outdated, custom software program for accounting and project management, the company explored new options and opportunities to help them improve. “Considering that 97 percent of our work is custom, we really needed a program that was flexible and could handle all of the unique processes and things we need to do,” said Kees.

“It’s important for our financial health that we get paid quickly, and by using the software, Bassett can give customers the documents they need” to move the billing process forward smoothly.

—Mike Kees, Manufacturing Project Manager, Bassett Mechanical

“We wanted a more efficient way to pull data for specific reports and allow us to track variations in labor and pricing. Custom work means every project is different, so it’s essential we find ways to cut down on operational inefficiencies wherever we can. We believed a flexible and feature-rich ERP [enterprise resource planning] software solution could help us do exactly that,” Kees noted.

Bassett Mechanical now uses Vista to manage accounting, project management, operations, and more. “The flexibility of Vista is so valuable to us,” said Kees. “The software allows the contractor to produce lots of helpful reports and respond to requests for analysis quickly.”

In addition to flexibility, Bassett Mechanical appreciates that the Vista solution is easy to use. After spending about 10 years as a field employee, Roy Immel became a project manager in Construction at Bassett, which required him to spend more time in the office, handling management and more administrative duties.

“I was not very familiar with construction technology, but using the project management features in Vista has been easy. I was able to pick up the software fairly quickly, and it’s easy to get around,” said Immel. “I can run reports myself without relying on accounting, so I save time and can see exactly what I need to when I need to. I have many favorite reports that I use on a consistent basis, and they help me stay on top of purchase orders, materials, contracts, billings, so much—even snapshots of job progress to stay informed and ahead of any problems.”

For more information, visit http://viewpoint.com.

Conti Corporation Cuts Installation Time with Erickson Incorporated Aerial Lift and Placement

Innovative aerial service provider Erickson Incorporated successfully conducted 13 chiller equipment lifts to the top of the JPM Chase building in Belleville, MI, in just two-and-a-half hours, allowing Conti Corporation to cut installation time dramatically. Erickson’s placement lifts saved time on the ground and also saved labor costs, because they were much more efficient than standard ground-based methods.

To prepare for such an extensive HVAC lift and placement project, Erickson operators worked with Conti project managers for three months, with an initial site visit in February to determine lift sequence, rigging, and clearance for crews to enter JPM Chase property. On the morning of March 28, Erickson’s S-64F Aircrane and crew arrived at the site. The chiller components previously prepared and staged in the parking lot next to the helicopter landing and fueling zone where Erickson and Conti managers had established a direct flight path to the rooftop to minimize flight time.

After a comprehensive safety briefing, the lift portion of the project began at 1:00 p.m., and all chiller components were successfully placed on the rooftop by 3:30 p.m. Erickson proved instrumental in accomplishing Conti Corporation’s goals in a short amount of time, while meeting safety expectations.

Although the lift was quickly completed, it was no small undertaking. All 13 placements were flown with steel cable rigging as four-point lifts, and package weights ranged from 2,118 pounds to 15,500 pounds. Erickson’s expert Aircrane crew consisted of three pilots and two radio personnel, one stationed on the ground for rigging, and one on the roof at the delivery site. For added safety, five road guards were stationed around the perimeter to ensure a secure area while the helicopter was working. This collaboration between Conti Corporation and Erickson Incorporated is an example of effective, efficient, and modern infrastructure installation and construction. Erickson’s Aircrane is uniquely designed, piloted and crewed to perform these kinds of specialized lifts and has successfully and safely placed more than 40,000 HVAC units on multistoried buildings, automobile plants, and aviation hangers across North America and Europe.

“The mechanical equipment was located in the middle of a 300,000-square-foot live data center complex. The pre-planning that Erickson and Conti undertook was exceptional and [the lift] went as planned. Each unit was precisely placed in a very efficient and safe manner. The Erickson Team took the time to visit the site twice, once meeting with the owner and the other with the Conti Team, making sure we all worked the plan and giving the customer a level of comfort,” said Victor Calleja, senior project manager for Conti Corporation.

For more information, visit http://ericksonaviation.com.

ACCO Gets Creative, Uses Single BITZER Compressor to Replace Tandem Units

When a major animation studio needed to replace a compressor and upgrade its systems, ACCO Engineered Systems took an unusual approach, replacing a tandem scroll set with a BITZER single semi-hermetic reciprocating 15-ton Varispeed™ model compressor with an integrated VSD. The new unit was easy to install and satisfied the customer’s demands.

The studio, based in Northern California, lost a 10-ton scroll that was part of a 20-ton circuit on a condensing unit that serves a projector room and 50 percent of a theater. Jay Blundell, ACCO’s project manager on this job, said the customer is very technology-driven, extremely conscious of noise and vibration, and concerned about energy savings.

Blundell consulted Steve Esslinger, BITZER’s regional sales manager, and requested a compressor recommendation to meet his customer’s needs while also converting the system to R407C. Rather than replace the tandem scroll set with new scrolls, Esslinger recommended BITZER’s 4PCS-15.F4Y Varispeed compressor. It operates from 25 Hz to 87 Hz, generating nearly 22 tons of capacity at 87 Hz. As the load on the auditorium changes, the compressor speed changes to match the load requirement. This seamless capacity control minimizes suction pressure fluctuations and cycling rates, thus reducing energy costs.

ACCO has performed numerous retrofit upgrades, so the mounting, piping, and wiring changes were easy. The built-in, maintenance-free, suction-gas-cooled VSD is fully parameterized for easy commissioning, and the unit has been running quietly and efficiently for months. Blundell said the customer is pleased with the results, and he intends to use the Varispeed for other retrofit jobs.

For more information, visit www.bitzerus.com or contact techsupport@bitzerus.com.

With Jay R. Smith Customized Solutions, Naval Hospital Completed Early, Under Budget

To overcome multiple and unusual challenges—including concerns about terrorism—Pan-Pacific Mechanical, in partnership with Murray Co., and A.O. Reed, collectively known as RPM, called on Jay R. Smith Mfg. Co. to accommodate unique specifications and complex coordination for the U.S. Navy’s Camp Pendleton Hospital Replacement Project.

The Camp Pendleton Hospital Replacement Project had a budget of over $450 million. The 70-acre site includes a 500,000-square-foot, multilevel medical hospital; a central utility plant; a 1,500-space multilevel parking structure; surface parking; and supporting facilities. The new hospital replaced the base hospital at Lake O’Neill, which was built in 1969.

RPM Rises to Unique Challenges

“The project schedule was exceptionally fast; it was a very aggressive schedule,” said Chris Young, project manager for Pan-Pacific. RPM also faced extra layers in the project’s chain of command. Navy construction is run through the Naval Facilities Engineering Command (NAVFAC), and a Resident Officer in Charge of Construction oversees the build.

For any other hospital in California, Pan-Pacific would typically operate under the California Plumbing Code. But because this was a U.S. Naval facility, RPM instead had to adhere to the International Plumbing Code as well as a multitude of other unique requirements mandated by NAVFAC.

Among those unique requirements, RPM had to take into consideration antiterrorism measures. “Terrorism on a military base is a big concern,” said Young. The storm and overflow drains had to be sized to accommodate over 3″ of rainfall per hour according to the 100-year storm statistical assumptions. “You have a very large-diameter overflow drain, up to 6–8″ in diameter. There was concern that someone could push a bomb in there from the ground level.”

Jay R. Smith Mfg. Co. custom-designed a downspout nozzle with a perforated latching stainless steel hinge cover that could be locked to prevent someone from inserting an object into the piping. Smith has since added the new design to their catalog, and it is now available as a standard offering. Young was so pleased with the clean look of the downspout nozzles that Pan- Pacific now uses them on other projects.

Pan-Pacific also eliminated the threaded nipple connection often used on the downspouts. “With the exterior of the building and the inside wall tight against one another, it was hard to get enough space between the sweep and the cow’s tongue to utilize a threaded nipple. Smith engineered the downspout nozzle so there are set screws around the perimeter of the downspout nozzle, which threads tight against the pipe, and the nozzle fits over the pipe to save space,” said Young.

Sustainable Solutions

Part of NAVFAC’s mission is to build and maintain sustainable facilities. Innovations used at the Camp Pendleton Naval Hospital include green roofs, photovoltaic cells (solar panels), solar hot water panels, and horizontal and vertical sunscreens. It is estimated these innovations will help to reduce energy consumption by 30 percent compared with a typical hospital.

To thwart potential terrorism at the new Camp Pendleton Naval Hospital, Jay R. Smith Mfg. Co. custom-designed a downspout nozzle with a perforated hinge cover that could be locked to prevent someone from inserting an object into the piping. The novel downspout resolved a tricky challenge for the RPM contracting group and has since been added to Jay R. Smith Mfg. Co.’s catalog.

The green roof at the Camp Pendleton Naval Hospital uses the Inverted Roof Membrane Assembly system, which must be installed over a structural concrete deck because of its weight. The green roof drains required staging. The drain bodies were initially installed on the job to make the concrete pour, and the tops (with perforated mesh screens) were shipped and installed later. All of the staging and shipping was coordinated to meet RPM’s schedule.

The drainage off a green roof surface is particularly important for maintaining optimum growing conditions for the plants, managing heavy rainfall without sustaining damage to growth due to erosion or pooling of water, and ensuring the sound engineering and structural integrity of the roof. Young explained that the selection of the roof drains was also important because of the hospital’s proximity to the Pacific Ocean and the aggressive nature of the air. The roof drain systems would not only have to withstand harsh weather but also hold up to the saltwater in the air.

While the weather conditions can be harsh on the top of a roof, down on the ground things are a bit different, especially in Oceanside, CA. The hospital design takes the temperate climate into consideration and provides an abundance of outdoor space for patients and their families.

Customized Connections

One of the outdoor amenities RPM had to provide for was an outdoor coffee kiosk. Anywhere you have food or beverage service, you need to provide hot water and sewer service for the staff to wash their hands. Young explained that an outdoor coffee kiosk connection box is not a standard item you can order from a catalog.

RPM turned to Smith to design a custom, stainless-steel, hot and cold water connection box. The custom-made box was set flush in the wall, which provided convenient hookup connections to hot and cold water service and sewer discharge when the kiosk was in use. The Camp Pendleton Naval Hospital construction project spanned four years. The hospital officially opened January 31, 2014.

For more information, visit www.jrsmith.com.

Donald C. Rodner, Inc. Cuts Labor Costs, Billing Time by Going Mobile

By adopting MobiliForms software from iBusiness Technologies, Donald C. Rodner, Inc. sped up their invoicing time and cut down on labor costs while still using the same forms and backend software employees were used to. Don Rodner, president, said, “When I saw a demonstration of MobiliForms at the MCAA conference, it blew my mind. I knew that we found the right solution.”

Donald C. Rodner, Inc., based in central New Jersey, is a full-service mechanical contractor. In serving their Fortune-500 customers, best-in-class service and tight record-keeping are musts. Like many other mechanical contractors, Rodner had managed his staff of highly trained, experienced service and plumbing technicians the old-fashioned way—with a variety of paper forms including work tickets, service orders, and time sheets. Billings were a week behind, handled in batches, as paperwork was all dropped on Mondays.

“When I saw a demonstration of MobiliForms at the MCAA conference, it blew my mind. I knew that we found the right solution.”

—Don Rodner, President, Donald C. Rodner, Inc.

Rodner knew that mobile technologies could help him operate his business more efficiently. He was not sure, though, which platform made the most sense or how his employees and customers would respond. Then, Rodner met the iBusiness Technologies team at an MCAA national event and saw how MobiliForms works.

The art of managing costs and internal processes dictates that any procedural change be carefully evaluated for its return on investment (ROI) and potential disruption. Rodner liked that MobiliForms does not require any change to backend software and also delivers the company’s familiar forms on the Apple iPad with multimedia capture. This meant that ROI was fast, and putting the system in place would not cause internal upheaval or resistance from employees.

Workdays now go more smoothly, as Rodner can track his technicians’ progress in real time, order parts as they are being used in the field, and ensure that invoices are sent to customers immediately. The dependability and durability of the iPads running MobiliForms turned out be a smart investment that is paying dividends daily.

For more information call 877-565-3261 or visit www.iBusiness-Tech.com.

Autodesk’s Smart Hardhat Software Alerts Workers to Onsite Dangers

Autodesk’s mobile software prototype communicates with dust and noise pollution sensors attached to a hardhat and tracks when levels become dangerous, offering the potential to dramatically decrease the number of injuries. Attendees of the MCAA Technology Conference: The Best of Now, The Best of Next, held just outside of Chicago, had a chance to try out the app and give feedback. Several members of the Autodesk research team came in from China to demonstrate the product, answer questions, and interact with potential users.

Construction continues to be one of the most dangerous occupations globally. Every year, hundreds of people are killed and many more injured at construction sites in the United States. The MCAA Technology Conference provided a first look at a sort of “smart” hardhat from Autodesk that incorporates technological advancements to improve safety on the jobsite.

The Autodesk system can also alert other workers when someone falls. Construction crews could locate workers, in near real-time, who had become injured or unconscious while in a remote corner of a building. In addition to identifying individual safety issues, the data from the sensors can be captured in a dashboard, giving holistic and historical views of where most accidents occur, along with other information. The software could also potentially eliminate the need for workers to punch in and out every time they arrive at or leave a jobsite.

Conference-goers offered the researchers ideas on how the construction industry might deploy these intelligent platforms to improve construction safety. For example, they suggested adding a sensor that could detect gas levels, particularly carbon monoxide, and others that could capture personal health parameters, like heart rate and body temperature. Autodesk is seeking companies that might be interested in piloting the helmet at their jobsite.

For more information, visit www.autodesk.com. Contact ling.zhao@autodesk.com to learn more about the pilot program.

Johnson Controls Offers High-Tech Connections to Monitor Equipment

Data Speeds Up Problem Diagnosis and Resolution, Saving Money

Johnson Controls, Inc. combined its YORK® chillers and Metasys® software technology to help contractors monitor the health of installed chillers during the warranty period so you can save time and money. Instead of sending multiple parties to the site to diagnose a problem, this connected approach gives you remote access to operating data and trends that help you pinpoint the root cause and resolve issues more quickly.

Managing product warranties can be a challenge for contractors, who are eager to complete projects on time and on budget for their clients. Monitoring chillers during the warranty period gives you a single point of accountability for warranty and maintenance. Implementing a proactive warranty response also creates value for the client.

The approach establishes a secure connection between the YORK chiller and the Metasys cloud-based analytics platform, enabling the following:

Critical alarms are monitored 24/7 by a UL-, FM-, and CSAA Five Diamond-certified remote operations center, which helps the contractor respond rapidly to identify and resolve problems.
Technicians have access to the chiller’s data and current operating conditions via smartphone, PC, or tablet.
Chiller operating data are collected and stored to analyze and troubleshoot issues.
Chiller health reports are provided during the warranty period to make sure issues are detected before they become serious problems.
Operating and trend data can be provided to local, regional, and global experts as needed to help troubleshoot and resolve problems.

When you have data to identify and manage warranty issues quickly, you can expect to resolve problems faster, which means getting paid faster and improving the overall project profitability. Connected systems also boost service levels and building performance, reducing downtime through remote, proactive issue resolution.

For more information, visit www.johnsoncontrols.com.

Johnson Controls connected Metasys software technology with YORK chillers to monitor chiller function. Contractors receive “health summary” reports like this one that help them diagnose and resolve problems quickly, saving time and money.

Arista Relies on Mitsubishi Electric Systems to Keep Restaurant Customers Comfortable in Any Weather

Thanks to years of experience serving the New York City area, Arista Air Conditioning Corporation knew that a Variable Refrigerant Flow (VRF) zoning system from Mitsubishi Electric US, Inc. Cooling & Heating Division would fit the bill for a new restaurant whose originally planned system proved unworkable. The VRF system also provided cost savings over the chilled water system originally specified.

System Meets NYC’s Strict New Noise Standards

Fogo de Chão® (Fogo), headquartered in Dallas, TX, is a Brazilian steakhouse known for its exceptional dining experience. Fogo began in Southern Brazil 35 years ago and has grown to 37 locations across Brazil, the United States, Puerto Rico, and Mexico. Fogo recently opened a New York City location directly across the street from the Museum of Modern Art, on West 53rd Street, between 5th and 6th Avenues.

The original HVAC design for the restaurant—a water plant on the roof—posed issues of code-compliance, cost, and unsightly ductwork. Dale Forester, the construction manager at Fogo, said, “Due to new noise standards, the water plant would have needed to come up to code. New York City has really strict regulations, and the noise levels from the previously planned HVAC design would have far exceeded them.”

Stanley Berger, CEO of Arista, based in the New York City borough of Queens, added, “Bringing in heat would have required bringing in many gas-fired boilers. That would have cost quite a bit.”

Arista Project Manager John Stewart further explained, “The chilled water system was spec’d for 180 tons with two 90-horsepower compressors. This was designed by an engineering firm outside of New York City and would have required an operating engineer at an additional cost.” Berger noted the chilled water system also would have required a new and expensive controls system.

Arista suggested an entirely differentroute: VRF. Berger said, “VRF’ssimultaneous cooling and heatingcapability means you can have heatcoming from one handler, coolingfrom another—any combination youwant. There’s tremendous energy savingsto that.”

Fogo did an energy analysis comparing the chilled water and VRF systems. Forester said, “We saw that using this [VRF] system over chilled water dropped the current load by 300 amps, offering tremendous savings.”

Zoning Guarantees Customer Comfort

Forester liked the idea of VRF but was unsure how the zoning would perform. Arista brought him to multiple installation sites around Manhattan. “In one steakhouse, I saw how the kitchen and dining room were separated into zones. This was in the wintertime, and the heat in the dining area was nice and warm. I was surprised at how well the dedicated zones worked,” Forester said.

The team was in agreement: VRF would save money while ensuring guest comfort. Berger said, “We’ve been working with Mitsubishi [Electric] for about 14 years and have installed several hundred jobs. It’s a fantastic product, and the machines operate under much more severe conditions than traditional systems can. It can be 120° in these spaces and VRF still works. We feel so positive about it that we put VRF in our own office.”

Two-Pipe System Saves Space

R2-Series units were selected for the majority of the project for their simultaneous cooling and heating capabilities. One Y-Series unit was selected for the main dining room. Berger explained, “It’s such a big area and it wasn’t necessary to have each air handler be able to operate on its own.”

The outdoor units went on the fifth floor setback. “We installed structural steel for the 84 tons of Mitsubishi [Electric] condensing units. We then ran piping from the roof down through an outside shaft into the building, connecting to about 30 air handlers,” said Berger. Forester added, “Other [VRF] brands use three-pipe systems. Mitsubishi [Electric] having just two pipes really helped.”

Fogo has since installed Mitsubishi Electric VRF at their Portland, OR, location. Forester said, “In Portland, the challenge was a lack of space on the roof. Mitsubishi [Electric] offered the most efficient use of space. Inside, Mitsubishi [Electric] solved the challenges of low ceilings and tight spaces quite easily with their two-pipe system. From these successes, we consider Mitsubishi [Electric] a preferred partner for this equipment.”

User-Friendly Monitoring Minimizes Maintenance

The system has been in place for over a year now, “and we’ve really had no problems at all. No mechanical issues, no repairs,” said Berger. Forester commented, “The HVAC works well. At the street entrance, when it’s 20° outside, if you walk in 10 feet, it’s warm. The zoning of the air also works really well with the three-level restaurant. There is a tendency for heat to rise, but the system can maintain all floors of the building at 72°. It’s designed very well.”

Part of that smart design is user-friendly monitoring. Fogo monitors its equipment via a control panel in the manager’s office. “It’s very simple to use for the amount of technology it has. There’s also diagnostic programming, online diagnostic programming, filter changes, etc.,that are all very easy to use,” said Forester.

Code-compliance has not been a problem, either. “With the variable frequency drives of the Mitsubishi [Electric] units, there is literally no noise,” said Forester.

For more information, visit www.mitsubishipro.com.

Arista CEO Stanley Berger knew from experience that Mitsubishi Electric’s VRF zoning system would easily meet New York City’s strict new noise standards thanks to its variable frequency drives.

The Mitsubishi Electric’s VRF zoning system has a user-friendly monitor to help stay on top of maintenance and diagnose any issues that arise. — Mitsubishi Electric’s VRF zoning system has a user-friendly monitor to help stay on top of maintenance and diagnose any issues that arise.

Message from Jim Allen, M/SC Chairman: Innovation on Your Side

In this issue of Smart Solutions, you will see excellent examples of how suppliers are working with you, the contractor, to meet increasingly complicated customer demands while ensuring you stay profitable. For example, to prevent potential terrorism at a new Naval hospital, Jay R. Smith Mfg. Co. custom-designed a downspout nozzle with a locking, hinged cover so no one could insert an object into the piping. To excavate live, buried telecommunication cables in Silicon Valley, Tri Tool Inc. created novel machinery to cut the pipe housing the cables. Aerial service provider Erickson Incorporated lifted tons of chiller equipment to a rooftop in a few hours, cutting Conti Corporation’s installation time dramatically.

Solving Dilemmas

Sometimes, the right products and services can help you out of a tough situation. Facing construction labor shortages in Houston, CFI Mechanical relied on building information modeling from Victaulic’s Construction Piping Services division for a new office tower. MacDonald Miller was relieved to find—midway through construction—that the HOLDRITE® HydroFlame™ sleeving system not only fixed leaks that had emerged but also resolved other challenges.

Other examples in this issue demonstrate the benefits of experience and knowing what a product can do. With years of experience with Mitsubishi Electric US, Inc. Cooling & Heating Division, Arista Air Conditioning Corporation knew that a Variable Refrigerant Flow (VRF) zoning system would fit the bill for a new restaurant whose originally planned system proved unworkable. Since The Warko Group convinced a medical device manufacturer to install APR Controls from Rawal Devices, Inc., the firm has finally been able to control humidity and temperature in its cleanrooms. TG Gallagher had only two consecutive weekends to replace a hospital’s aging cooling towers, so they selected Baltimore Aircoil Company towers designed to make installation and upgrades easy. ACCO Engineered Systems took an unusual approach to a compressor retrofit, replacing a tandem scroll set with a single BITZER compressor for an efficient, quiet solution.

Software Solutions

More software solutions are emerging to help you improve business operations. Read how Johnson Controls, Inc. combined its YORK® chillers and Metasys® software to help contractors monitor chillers, pinpoint problems, and resolve issues quickly. With MobiliForms from iBusiness Technologies, Donald C. Rodner, Inc. sped up their invoicing time and cut labor costs while keeping the forms and backend software employees were used to. By replacing their outdated software with easy-to-use, flexible Vista™ by Viewpoint, Bassett Mechanical improved efficiency and streamlined billing processes. Looking ahead, Autodesk is developing software for a “smart” hardhat with sensors that alerts workers to dangers.

We hope this issue spurs you to think about how your suppliers can help you save time, improve productivity, and meet complex customer needs.

Jim Allen, Chairman

Mitsubishi Electric’s VRF Zoning Systems Slash Electric, Gas Costs for Franklin Energy

By installing a Variable Refrigerant Flow (VRF) zoning system from Mitsubishi Electric US Cooling & Heating Division in its new headquarters, Franklin Energy Services, LLC saved 32 percent in electricity and 48 percent in gas in its first year, compared with average usage for a comparable building. The savings are all the more impressive because the new headquarters are in a historic building in Port Washington, WI.

Franklin Energy has consulted with utilities, municipalities, and states to create energy-efficiency programs for their commercial, industrial, agricultural, and residential customers since 1994. For example, Franklin Energy’s Focus on Energy program has been working with Wisconsin residents and businesses for more than 10 years to install cost-effective energy-efficient and renewable energy projects.

A Showcase for Energy Efficiency

Franklin Energy moved its 10,000-square-foot national headquarters into a historic structure on the shores of Lake Michigan in January 2011. Formerly the Smith Brothers processing plant (Port Washington was once famous for the national distribution of white fish, chub, perch, and trout), the building is on the National Register for Historic Places. According to Franklin Energy CEO Paul Schueller, the company had always made its headquarters a showcase for the firm’s approach to energy efficiency. “We have a long history of selecting underutilized buildings for our headquarters and regional offices,” Schueller said.

Energy Usage	CBECS Average	Franklin Energy Actual	Savings
Electric	17.9 kWh/ft2/y	12.2 kWh/ft2/y	32%
Gas	42.3 ft3/ft2/y	21.9 ft3/ft2/y	48%

The choice to use Mitsubishi Electric’s VRF zoning technology was based on several factors:

Energy savings
Ease of installation
Superb quietness (sound attenuation)
A great ability for load-sharing (not possible with conventional systems)
Ingenious INVERTER®-driven compressor
Small footprint and lightweight modularity of the outdoor units
Industry-exclusive simultaneous cooling and heating ability

Data Demonstrate Savings

Mark T. Kuntz, P.E., Mitsubishi Electric’s vice president of Marketing & Engineered Solutions, said, “Franklin Energy is a very high-profile project for us. They have an excellent reputation for helping utilities and municipalities all over the U.S. achieve impressive energy savings through sound program implementation practices.”

Kuntz said that Mitsubishi Electric is delighted that Franklin Energy selected the Mitsubishi Electric VRF zoning system for its headquarters building. “Not only do we respect Franklin Energy’s work in the area of energy efficiency, but the installation provided an opportunity for our engineers to collect 12 months of solid energy-savings quantification,” Kuntz said.

Using actual utility meter data as well as measured data from an energy monitoring system, the results showed significant energy savings compared to the average Commercial Buildings Energy Consumption Survey (CBECS) energy usage for a building of its size and construction type (see the chart).

These results validated the original energy model projections. The actual energy usage for electricity and gas were within one and five percent of the models, respectively. While saving a great deal of energy is an excellent result, comfort was still a top priority for Franklin Energy and the people working on site.

“This Mitsubishi Electric VRF zoning system has been a lifesaver for individual comfort and for helping us save on energy costs.”

— Paul Schueller, CEO, Franklin Energy

By installing Mitsubishi Electric’s VRF zoning system in its new headquarters, energy-efficiency consultants Franklin Energy saved 32 percent in electricity and 48 percent in gas in their first year. The individual room controls maximize comfort for the occupants.

“Because of the building’s orientation and outdated glass windows, solar gain was a huge issue for our HVAC systems selection,” Schueller said. “This Mitsubishi Electric VRF zoning system has been a lifesaver for individual comfort and for helping us save on energy costs. Because of the Mitsubishi Electric INVERTER technology and individual room controls, the perimeter offices in this old building have been very comfortable in all seasons.”

For more information, visit www.mitsubishipro.com.

The Real Cost of a Lost Laptop Is $49,246

Laptop Computer and Mobile Device Security Tips from CNA

Laptop computers are vital tools used by a wide population of contractors and are also the number-one risk they are facing due to theft. Since laptop computers and handheld devices are not typically used in a fixed, securable location such as a jobsite, additional measures are needed to protect them.

A formal security policy detailing end-user responsibility for securing these devices and the data they contain is essential. Devices should never be left unattended.
Cable locks and docking stations should be used but only when the device is left in a secure location, such as an office, for short periods.
- These security methods are easily compromised, and higher-security options should be used when leaving a laptop in an office overnight (locked in storage area, file cabinet, etc.).
Travel procedures should address common high-risk situations:
- Avoid storage in automobiles.
- Do not leave devices unattended in hotel rooms.
- Airport security areas, check-in counters, baggage claim, restrooms, food courts, and curbside pick-up areas are all high-risk areas for theft of portable devices. Warn end-users to maintain extra vigilance in these areas.

Potential losses associated with exposure of sensitive data stored on stolen laptop and desktop computers can be much greater than the cost associated with replacing the stolen equipment. A key finding of the Ponemon Institute’s The Cost of a Lost Laptop study conducted in 2009 was that the average value of a lost laptop was $49,246. This value is based on seven cost components: replacement cost, detection, forensics, data breach, lost intellectual property costs, lost productivity, and legal, consulting, and regulatory expenses. Occurrence of a data breach represents 80 percent of the cost. Therefore, it is important to take additional steps to prevent losses related to data breaches associated with the theft of data storage devices and media.

First, carefully evaluate the need for storage of sensitive information on any type of portable device or removable media. In many cases, it will be determined that the need for storing information on these difficult-to-secure devices is not worth the benefit given today’s threat environment.
Where possible, prohibit such storage in an information security policy but also evaluate technical means of preventing this data leakage—disabling or monitoring usage of USB ports, content filtering, and other methods are possible.
If it is determined that storage on portable devices or removable media is absolutely necessary, these data must be protected, and encryption is the most common means of doing so.

Encryption is the process of making data unreadable except to those who possess the appropriate key to decode and read the data. Many state breach notification laws do not mandate notification of affected parties if the data involved are encrypted. Following are two resources for encrypting stored data:

EFS—The Encrypted File System has been available on professional versions of Microsoft Windows® since Windows 2000. EFS allows file-level encryption of sensitive files. Additionally, Microsoft BitLocker® Drive Encryption is available on Microsoft Windows XP and Vista®. With BitLocker, all data on a PC can be encrypted, preventing unauthorized users from being able to circumvent operating system passwords and access data.

The Data Encryption Toolkit for Mobile PCs, from Microsoft, provides guidance and software tools needed to effectively use both EFS and BitLocker for encryption of sensitive data. See http://technet.microsoft.com/en-us/library/cc500474.aspx.

For more information, visit https://www.cna.com.

MCAA thanks CNA for being a benefactor of MCAA 2015.

This information is presented for illustrative purposes only and has been developed from sources believed to be reliable. CNA accepts no responsibility for the accuracy or completeness of this information. CNA is a registered trademark of CNA Financial Corporation. Copyright © 2014 CNA. All rights reserved.

With Hurry-Up Offense and Zurn Products, Orlando’s Citrus Bowl Stadium Renovation Completed in Ten Months

When the scoreboard of the original Orlando Citrus Bowl Stadium was torn down in January 2014, the project team began a hurry-up offense to complete a roughly $200-million renovation in only ten months. Zurn Industries, LLC was drafted to provide its products and to meet the challenges of an expedited project timeline with made-to-order requirements.

Everything below the stadium’s upper deck was targeted for demolition and reconstruction to update the storied venue, which opened in 1936. The game plan provides Orlando, FL, a modernized stadium the city can use to host College Football Playoff games, World Cup soccer, and other major entertainment events that require a big, modern venue.

The large-scale renovation included new restrooms, concessions, kitchen facilities, and a team facilities building, as well as locker rooms for athletes and game officials. Zurn products were specified for all of these spaces.

“Zurn’s Custom Specification Drainage products and carrier banks were engineered, approved, ordered, and shipped in less than four weeks,” said Bill Verdecchia, director of Specification Drainage Product Marketing & Engineering for Zurn.

The roster of products used in this project is lengthy and filled with high-performance veterans, including stainless steel linear floor drains, lavatory and urinal carrier banks, closet carriers, stormwater drainage, custom debris covers, wall hydrants, cleanouts and light-duty grease traps, floor sinks, and floor drain stabilizers.

Plumbing contractors found that using Zurn carriers enabled them to cut the installation time in half for water closets, urinals, and lavatories. They also found that using Zurn products allowed them to prefabricate sturdy units that were then moved to the site and installed with no damage or leaks.

Construction crews worked in 24-hour shifts, and everyone associated with the project was laser-focused on the play clock. Products that allowed for fast, easy installation were essential.

The Citrus Bowl project demonstrates the breadth of engineered water solutions that Zurn provides. “It makes it so much easier for everyone involved to specify, install, and use products that are designed to work as total building systems,” said Frank Schaetzke, National Sales Manager for Zurn. “And needless to say, this is a huge building.”

Florida Citrus Sports runs major events in the Citrus Bowl. The group was instrumental in getting the stadium renovated.

“Just seeing it in real life, to be able to walk into the bowl—it just blows me away,” said Steve Hogan, CEO of Florida Citrus Sports, speaking to the Orlando Sentinel. “Most of the country that would look at bringing business to Orlando has heard about this now, but once they actually come and experience it, I think all bets are off.”

The new stadium was unveiled just days before the annual Florida Blue Florida Classic football game November 22, 2014. The stadium hosted the nationally televised Buffalo Wild Wings Citrus Bowl on New Year’s Day.

For more information, visit www.zurn.com.

MCAA thanks Zurn Industries for being a benefactor of MCAA 2015.

Prefabricating Zurn carrier systems allowed quick installation of plumbing systems in the modernized Citrus Bowl Stadium. The sturdy prefabricated systems were installed onsite with no damages or leaks.

“Zurn’s Custom Specification Drainage products and carrier banks were engineered, approved, ordered, and shipped in less than four weeks,” said Bill Verdecchia, director of Specification Drainage Product Marketing & Engineering for Zurn. Here, the prefabricated carriers are waiting to be transported to the Citrus Bowl for installation.

JS Thomas Service, Inc., Gets Paid Faster Using MobiliForms from iBusiness Technologies

By making the transition from paper service tickets to iPads® using iBusiness Technologies’ MobiliForms, JS Thomas Service, Inc., sped up its billing process, so now they get paid faster. The move also improved customer satisfaction. Because MobiliForms is compatible with QuickBooks®, the switch was easy.

JS Thomas is a full-line mechanical service company supporting customers in the commercial office, medical, manufacturing, industrial, and data center businesses throughout Atlanta and north Georgia. “We have some of the best technicians in the industry working for us,” proudly stated Jim F. Thomas, president and second generation owner of JS Thomas. “Our HVAC service team members rank among the best in Atlanta in expertise—from two-ton split systems to 1,000-plus-ton centrifugal chillers. Unfortunately, their handwriting and paperwork organization skills sometimes do not rise to the same top-notch levels.”

“I am most pleased with how MobiliForms has accelerated our billing process, positively impacting our cash flow”

—Jim F. Thomas, President, JS Thomas Service, Inc.

Thomas does not hire his field team members on the basis of managing paperwork, however, and his home office staff did their best to handle the paper service tickets that came in weekly from the field. When Thomas read in Smart Solutions about how iBusiness Technologies is working with other MCAA member companies to convert paper forms and project documents to mobile, he knew he had found a solution to his burdensome and common problem.

iBusiness Technologies has partnered with Apple® to provide the iPad-based MobiliForms solution to MCAA members. Field techs are now interactively completing their familiar, identical forms and instantly sending them back to the office for same-day invoicing. This process eliminates paper forms that can be difficult to read, get lost, or need to be driven or shipped back to the office. Technicians love the ability to capture images and even mechanical sounds right into MobiliForms. Customers like signing on the iPad. The compatibility of MobiliForms with QuickBooks provides JS Thomas with a low-cost, powerful, and complete business system with mobile capabilities.

Thomas collaborated with iBusiness Technologies’ programming team to bring to life his familiar service ticket, which now easily captures essential information and automatically computes parts, materials, and labor hours. JS Thomas’ existing refrigerant log, pricing request sheet, and time sheet are also now all iPad-based.

Using 13 iPads, the JS Thomas service team stores completed forms and project documentation in the cloud for immediate access by the office. This instant accessibility boosts customer satisfaction by speeding up processing and ensuring tight recordkeeping.

For Thomas, the ability to leverage mobile solutions for daily invoicing without the upheaval of replacing his software was a tremendous benefit of the transition from paper to MobiliForms. “I saw MobiliForms as a way to neaten service tickets, project the expertise of our technicians, and look more professional to our customers, but I am most pleased with how MobiliForms has accelerated our billing process, positively impacting our cash flow.”

For more information call 877-565-3261 or visit iBusiness-Tech.com.

With a Lift from Erickson, Thomas J. Dyer’s Installation, Labor Costs Plummet

Toyota Motor Manufacturing Plant’s Rooftop Units Placed in Less Than an Hour

Thomas J. Dyer placed six air handling units and a condenser on a plant roof in less than one hour by relying on innovative aerial service provider Erickson Incorporated. Thomas J. Dyer commissioned Erickson to lift and place the HVAC components onto curb installations on top of the Toyota Motor Manufacturing plant in Georgetown, KY. After the air handling units and condenser were placed on the single-story building by helicopter, Thomas J. Dyer crews completed the installation.

On July 12, 2014, Erickson’s Aircrane helicopter and crew arrived on the jobsite page8-top at 6:15 a.m., and Thomas J. Dyer and Erickson crews conducted a safety briefing at 6:30 a.m. The lift portion of the project began at 7:00 a.m., and the HVAC components were safely placed on the roof by 7:34 a.m. With a total of seven lifts and a flight time of just 34 minutes, Erickson proved instrumental in accomplishing Thomas J. Dyer’s goals in a short time while exceeding safety expectations. Although the lift was quickly completed, it was no small undertaking. All seven placements were flown with steel cable rigging as 4-point lifts, and package weights ranged from 3,950 pounds to 12,800 pounds.

Thomas J. Dyer’s collaboration with Erickson represents an effective, efficient, and modern approach to infrastructure installation and construction. Erickson’s placement lifts not only saved time on the ground, but also saved labor costs because they were much more efficient than standard ground-based methods. In addition, the project was approved by the Owner Controlled Insurance Program (OCIP) in which Toyota is enrolled.

This kind of project is not new to Erickson. The company prides itself on the delivery and installation of heavyweight ventilation and air conditioning units onto a variety of challenging rooftops and structures. Erickson’s Aircrane is uniquely designed, piloted, and crewed to perform specialized lifts. Erickson has successfully and safely placed over 40,000 HVAC units onto multistoried buildings, automobile plants, and aviation hangers across North America and Europe.

For more information, visit ericksonaviation.com.

Sauer Group Increases Productivity by 300 Percent with Tri Tool High-Performance Welding Solutions

Sauer Group wanted to ensure high-quality welds while reducing time and costs on a natural gas processing station project, so they used Tri Tool Inc.’s AdaptARC® system, configured for flux core arc welding (FCAW) deposition, which increased productivity 300 percent over traditional stick welding. Brian Stahovec, project superintendent for Sauer Group, said, “The welding process we’re using was developed by Tri Tool in conjunction with Sauer especially for this project. Utilizing that method, we’ve been able to not only cut costs but also make sure the schedule’s been maintained.”

The project involved a cryogenic natural gas processing and compressor station for the Marcellus and Utica Shales where oil and gas were separated and the final product was delivered directly from the active well using horizontal drilling and hydraulic fracturing. The Sauer Group’s work on the project for Mark West Energy Partners was the largest undertaking of its kind in its 100-plus-year history.

The project scope called for outdoor installation of 1,920 linear feet of 36”–42” outside-diameter X 1” wall finger-type slug catchers fabricated from seam-welded High Grade API 5L X70 pressure piping using ER70S-2 high-tensile-strength filler material. Tasks identified in initial planning included restoring shop-fabricated spool ends to specification, precision-machining a total of 54 weld joints to ensure proper fit-up, and performing 100-percent X-ray welds at accelerated deposition rates.

To achieve their goals, Sauer Group decided to work with an onsite field services subcontractor who was also an original equipment manufacturer (OEM) of welding and portable machine tools. Prior experience with Tri Tool’s field machining services led Sauer Group to consult Tri Tool for a comprehensive field machining and welding solution.

Using Tri Tool’s AdaptARC system increased Sauer Group’s productivity 300 percent over traditional stick welding, saving the contractor two to three shifts of welding time.

Working with Sauer Group and Mark West Energy Partners, Tri Tool Field Services developed, tested, and validated weld procedures per ASME B31.8 and deployed certified project managers, machinists, and welders using patented Tri Tool portable machine tools and AdaptARC multiprocess welding systems. To meet schedule constraints, two sets of two weld heads, each operating in tandem and loaded with 1/16″ wire, were run simultaneously, laying a total of 160–240 lb. of filler material per day. The AdaptARC system saved the contractor two to three shifts of welding time.

“Whether it’s safety, whether it’s quality, whether it’s just implementing their systems and bringing personnel on board, [the partnership with Tri Tool has] been an added plus to the entire project, and I highly recommend them,” said Stahovec.

Emergent needs presented challenges to both quality and schedule. Out-of-round pipe identified onsite required inside-diameter (I.D.) weld overlay and counterboring to achieve fit-up while maintaining minimum wall thickness. Working outdoors subjected critical equipment to severe conditions, but the rugged construction of the AdaptARC plus the initial assessment and qualifications of the FCAW processes resulted in a remarkably low weld rejection rate. The welding system is so easy to use that Tri Tool has trained and certified two additional local welders who are now contributing on this project.

To create precision welds on a tight schedule for a cryogenic natural gas processing and compressor station in the Marcellus and Utica Shales, Sauer Group partnered with Tri Tool Field Services, which developed weld procedures and deployed workers using Tri Tool portable machine tools and AdaptARC multiprocess welding systems.

“Our continued diligence and focus on quality in conjunction with the use of the AdaptARC system has further reduced our rejection rate to below .5 percent, an industry ‘top tier’ performance indicator for this type of work,” said Pat Flippen, vice president of Tri Tool Field Services.

Tri Tool is the only service provider deploying both precision field machining and mechanized welding systems of its own patented design and manufacture, making it the only true sole source for both specialty field machining and welding solutions. This unique set of experience, capabilities, manufacturing capacity, and inventory enabled Tri Tool to redesign a torch head to perform the large-bore eccentric I.D. weld overlay, counterbore, weld prep, and finished weld in under 36 hours from identification to weld-out.

A field machinist makes preparations to ensure a reliable weld on the pipes for a natural gas processing and compressor station. Tri Tool’s attention to quality and safety enabled Sauer Group to perform excellent welds at a rapid pace, meeting the project’s schedule constraints.

Tri Tool’s expertise lies in applications engineering and execution of industry-specific field machining and welding solutions. Tri Tool Inc. is committed to the safe and successful completion of its clients’ projects, on schedule and within budget.

“We found a nice partner with Tri Tool,” said Dave Kretin, project manager for Sauer Group. “Due to the quality of people they had that developed the welding procedure, we were basically doing about 7″ per minute with both welders running and putting down about 3/16″ thickness [per pass]. That is outstanding—we’re getting 6 hours a weld! A few of the QA/QC guys and the nondestructive testing companies said that they’ve never seen a film that looked so good after we shot the weld. They’re all 100% X-rays. Tri Tool’s done an outstanding job, and I really enjoyed working with them.”

For more information, visit www.tritool.com.

Carrier Helps Hospital Earn LEED Certification and $117,000 Energy Rebate

To meet the Shore Medical Center’s goal of obtaining LEED® certification, Carrier specified a range of chillers and a web-based integration system for its new Surgical Pavilion, earning the Medical Center a $117,000 rebate from the New Jersey Clean Energy Program™ in the process.

Shore Medical Center, formerly known as Shore Memorial Hospital, provides a broad range of health care services to the people of southern New Jersey. The main campus is located in Somers Point, with a regional Dialysis Center in Northfield, about fourand- a-half miles away. To meet the needs of a diverse population in the 21st century, the hospital leadership decided to add a new Surgical Pavilion where physicians and staff in the facility’s numerous Centers of Excellence could employ the latest technology to provide optimal patient care in safe, comfortable surroundings. The resulting pavilion houses 11 state-of-the-art surgical suites as well as beautifully appointed patient and family areas.

Hospital leadership wanted to maximize energy efficiency in the cooling system of the new facility as one step toward earning LEED certification. Other sustainable features included a white roof and rooftop gardens and the exclusive use of building materials manufactured within 500 miles of Somers Point.

Carrier installed an i-Vu Pro web-based user interface to integrate new Carrier AquaEdge 23XRV water-cooled chillers with ancillary equipment and the existing BACnet Building Automation System at Shore Medical Center, which saves the engineering staff both time and money.

To meet the customer’s efficiency goals, Carrier recommended an “N+1” cooling system in which each component has a backup device for safety and reliability—specifying two 23XRV AquaEdge™ chillers and one 30HXC AquaForce® chiller as an emergency backup. With a peak facility load of 700 tons, the 200-ton 30HXC chiller provides emergency redundancy for either 500-ton 23XRV chiller. The 23XRV chillers have an Integrated Part Load Value (IPLV) of .326 kW/ton, a marker of very high efficiency in operation.

“While the technical capabilities of the i-Vu interface are excellent, it’s the savings—in both time and money—of combining system monitoring, diagnostics, and notification by email that make it an invaluable tool for us.”

—Anthony Carino, Chief Engineer, Shore Medical Center

Darryl Hitchcock, sales manager at Carrier, said, “The 23XRV AquaEdge chillers are so reliable that even when, at start-up, the cooling towers were returning water that was above optimum temperature, the chillers just kept running efficiently while we resolved the situation.”

Carrier also installed an i-Vu®Pro web-based user interface to integrate the new chillers with some existing equipment and the existing BACnet® Building Automation System. Anthony Carino, chief engineer for Shore Medical Center, said, “The trending capabilities of the i-Vu interface are superb: we know at any moment what any given component is doing. In the event of an alarm, the system will alert me by text or email so I can act immediately, and the diagnostics make it simple to determine the problem.

“In addition, the i-Vu interface is a real time- and energy-saver because we can monitor the heat pumps at the Dialysis Center from our offices here on the main campus, which saves us a 20-minute drive each way,” Carino continued. “We can tell immediately whether there is a problem in Northfield, without losing all that valuable time.”

Carino went on to say, “While the technical capabilities of the i-Vu interface are excellent, it’s the savings—in both time and money—of combining system monitoring, diagnostics, and notification by email that make it an invaluable tool for us.”

Shore Medical Center’s efforts to build a sustainable health care facility were rewarded. The 23XRV AquaEdge chillers qualified for a $117,000 rebate from the New Jersey Clean Energy Program, an energy-efficiency initiative of the New Jersey Board of Public Utilities. Shore Medical Center achieved LEED Silver certification for the new Surgical Pavilion.

For more information, call 800-CARRIER or visit www.commercial.carrier.com.

MCAA thanks Carrier for being a major sponsor of MCAA 2015.

Geiler Plumbing Cuts Installation Times with Wayne Water Systems’ Blue Angel Pumps

Geiler Plumbing found that using Wayne Water Systems’ Blue Angel Pumps cut down their installation time, improving overall productivity. The new Blue Angel Pumps’ Pre- Assembled Back-Up and Primary System combines all the components needed for a sump pump with a high-quality backup pump and an autodialer that can notify up to five numbers.

“It’s definitely easier (the installation). You’re not playing with acid, and you don’t have to put prongs in anywhere and make sure you have everything wired up correctly,” said Jose Varos, technician for Geiler Plumbing. “With the old ones, you’d have about 15 lead wires coming over and each one has to be hooked to a certain side. It’s nice that they (Blue Angel) color-code all of them.”

The cast-iron primary pump pushes 60 gallons per minute, while the fully submersible thermoplastic backup pump pushes 47. The backup system includes connection ports for third-party security system notification, while the autodialer allows plumbers to input up to five numbers (including their own) to be alerted in the event flooding occurs. Is this beneficial to the consumer? “I think it is, for quite a few reasons,” Varos said. “People never go down and look at their sump pump. I’ve gone out on inspections, and it’s full to the drain tile, where it’s been running for who knows how long.”

A bright LCD screen displays the time, date, and various messages about the current state of the primary and backup pumps. The system is also extremely quiet while it runs. “It is super quiet. It’s very nice. The only thing I hear is the check-valve when it closes, and that’s how I know it’s actually working.” When he first installed a system, Varos said, “I expected to go downstairs and see water everywhere because of how quiet the pump was.”

Varos continued, “It’s just really nice—for ease of installation, the simplicity, and how user-friendly it is.”

For more information, visit www.waynewatersystems.com.

The Waldinger Corporation Finds PENTA Mobile App Drives Productivity and Sales

The Waldinger Corporation—a leading HVAC, plumbing, sheet metal, electrical, and service contractor with local presence throughout Iowa, Nebraska, Kansas, and Missouri—expected that using PENTA Technologies’ Mobile Field Service application would improve productivity and save money when it came to capturing and keying in information. “What we may have underestimated is the ability of our sales team to use the added abilities to market our services,” said Dave Miller, Waldinger’s senior vice president of Operations. “We have definitely had proven results on the sales and marketing fronts.”

Waldinger’s first mobile experiences were with the original Windows® version of the PENTA Mobile application, which were running on a small handheld device, the ES400. The solution accomplished many of their goals, but it was not as intuitive as they would have liked. “The new iOS version that we are now running on iPad minis™ has been extremely well-received,” said Miller. “The software is much more intuitive and has many new features, and the hardware is stable.”

The company adopted PENTA Mobile Field Service so that its technicians would have more complete information to better serve customers. Technicians can now see previous service history by piece of equipment, so they know more going into the call.

Waldinger also wanted to eliminate duplication of efforts. Miller explained, “Technicians used to write down a description of work, inventory usage, labor, meter readings, and purchases only to have someone in the office rekey all of that information into PENTA. Now, PENTA Mobile captures the information, we review it in the office, and then it’s automatically entered” into the PENTA system used in the home office.

In addition, Waldinger sought to facilitate equipment service history reporting. “Since this mobile solution allows us to easily track and report service history by piece of equipment, we can communicate more effectively with facility directors. This has been an effective way to sell our services to larger chain accounts,” said Miller.

The original Windows mobile version of the software was frustrating for some technicians, but the new iOS version is quite the opposite, Miller pointed out. “All of our technicians have embraced PENTA Mobile Field Service… and you’d have a hard time prying it out of their hands!”

Miller said Waldinger is just scratching the surface of the benefits that can be realized from mobile technologies. “We will certainly be looking to expand our use over the coming years to improve efficiencies and to provide more benefits to our customers,” he noted.

Miller added that PENTA Mobile Field Service was simple to implement. “We selected a pilot group for testing, which allowed us to determine best practices for the solution before rolling it out to the rest of our company,” he said. He suggested other companies planning to implement mobile applications “start small, develop your list of best practices, and then move to your larger rollout.”

For more information, visit www.penta.com.