Smart Solutions Category: HVAC

New England Sheet Metal Works Sees Daikin Chiller as Perfect Fit for Historic Building

New England Sheet Metal Works, Inc. (NESM) chose a Daikin Magnitude® chiller to upgrade the historic T.W. Patterson building in downtown Fresno, CA, because its compact design fit the tight spaces of the 93-year-old building. NESM provided temporary cooling, engineering design of the new water-cooled applied system, and services that included the installation of the Magnitude chiller, related piping, and a cooling tower.

“Both NESM and Patterson building ownership are passionate about downtown and have long histories here in Fresno,” said Jim Boone, president of NESM. “Our firm is very familiar with Daikin and has the experience required to bring the historic Patterson building this state-of-the art chiller technology.”

State-of-the-Art, Then and Now

The Patterson building was the first multistory building to feature air conditioning in the United States back in the 1920s. The recent HVAC upgrade was a chance to show advanced technology and problem-solving at its finest. The eight-story building houses nearly 152,000 square feet of office space along Fresno’s Fulton Mall on Tulare Street.

In 2014, the building’s existing 20-year-old water-cooled centrifugal chiller needed replacement. Owners T.W. Patterson Partnership turned to temporary cooling while pursuing options. In early 2015, the Patterson Building owners conducted an ASHRAE Level-2 audit under the Central Valley Business Energy Tune-Up (BETU) program, sponsored by utility company Pacific Gas & Electric (PG&E) and managed by the City of Fresno.

The audit provided owners with an extensive analysis of energy usage and equipment options based on the type of chiller. “We visited the site a few times in early 2015 and our work included helping the owner evaluate options for the chiller’s replacement using a new air-or water-cooled chiller, or whether to refurbish the existing chiller,” said Ignacio Robles, P.E., senior program manager and energy consultant, on behalf of the Central Valley BETU program. “Our 20-year payback analysis showed a water-cooled chiller would be about half the cost of a typical air-cooled chiller, saving ownership about $1 million versus an air-cooled chiller.”

When they installed new Daikin chillers, NESM maintained the integrity of the historic T.W. Patterson Building—a high priority for the owners—while bringing 21st-century technology to bear on the cooling system.

T. W. Patterson Partnership evaluated a number of proposals from equipment suppliers and ultimately decided to stay with a water-cooled solution with the same manufacturer while upgrading to state-of-the-art technology. “A major driver for us was we were extracting water, cooling our systems down, and discharging our water. We weren’t ecofriendly, so we decided to put in a closed-loop system with the new Daikin Magnitude chiller and add a cooling tower,” said Rick Roush, general partner for T.W. Patterson Partnership in Fresno.

Daikin chillers installed by NESM not only met the cooling needs for this Fresno landmark but also helped owners improve energy efficiency, reducing electrical costs by an estimated 25 percent.

“We started the process of working on the project in spring 2014 while the owner reviewed options,” said Eric Dinneen, Daikin Applied representative in Fresno. “Without a doubt, the energy savings of the magnetic-bearing chiller put the decision over the top. It was also selected for its compact design.”

The 284-ton capacity Magnitude chiller serves 92,000 square feet of office space at the Patterson building. “The whole package with the Daikin chiller offered much greater savings and operating efficiency than with the closest competitor,” Roush said.

“The Daikin magnetic-bearing technology was so intriguing to us, the gravity feed, the lack of friction, no oil, and the quiet operation all made so much sense” Roush continued. “The PG&E/City of Fresno program showed us an average compilation of how efficiently the chiller would run, with even greater savings when used in tandem with the dual compressors.”

Installation Poses Challenges

A number of upgrades to the building were required to accommodate the Daikin Magnitude chiller. “It was really important for us to maintain the history and integrity of the building. Part of the challenge was that there were no mechanical drawings available for the existing system, which added a discovery component to the project,” said Richard Walker, account manager for the mechanical solutions team at NESM.

In spring 2015, temporary cooling was located outside the building in a semi-trailer, and preparations were made to replace the existing chiller located in the mechanical room off the underground parking ramp. “Low clearances in the building presented installation challenges. Routing of the condenser water pipe to the second story roof was a critical part of the installation,” Walker said.

The cooling tower was installed on the second-floor rooftop, and 200 feet of eight-inch condenser water supply and return piping was installed, running from the chiller across the parking garage and up to the cooling tower. Chilled water piping was connected to the existing piping in the lower level. NESM also provided controls integration with the existing building automation system (BAS) and installed a refrigeration alarm system with an exhaust fan to provide fresh air in the event of a refrigerant leak.

“One of the most difficult challenges of the entire project was getting the old chiller out of the building and navigating the tight spaces in the underground parking garage. The ramp has about a 15° angle,” said Chuck Cox, project manager with NESM. Casters, fabricated by NESM to accommodate the 15,000- pound weight of the old chiller, were used to pull the chiller out of the underground parking garage with low-clearance forklifts at each end.

On the same day the old chiller was removed, the 11,000-pound Magnitude chiller was disassembled, which required draining of the refrigerant system. The dual compressors were stacked on the same caster system, transferred down the ramp, and maneuvered into the lower mechanical room. The chiller is situated in the same location as the former chiller, near the original 1926-era air conditioning system, which remains in the building.

Wayne Wimer, building superintendent at the T.W. Patterson building, worked closely with NESM to facilitate the required changes and oversaw those made directly by building owners. To accommodate the new chiller, owners made additional investments that included removing a wall and relocating two electrical panels as well as installing a step-up transformer and new circuit breakers to meet the voltage requirement of the new chiller.

“Most buildings are now wired to 480 voltage and have transformers located outside their buildings. Because our building is wired to 208 voltage, we had to have a dedicated step-up transfer installed near our extra circuit breakers in the mechanical area to accommodate the new chiller,” Wimer said.

Historic buildings like the T.W. Patterson Building in Fresno, CA, pose challenges to contractors tasked with upgrades. For example, NESM removed the old chillers and installed the new Daikin chillers while navigating a 15° underground parking ramp.

Energy Savings Realized

Installations, including piping and ductwork, were completed in June, and by July 1, 2015, the new equipment was up and running. Wimer noted, “It’s very interesting to walk into our basement and have the very oldest and very newest in chiller technology.” Wimer is among many who appreciate the quiet operation of the chiller. Every morning, he checks the Magnitude chiller performance data and also monitors the system through the facility’s BAS system on a PC and tablet. “The new chiller has made a big difference in our occupant comfort and level of control across our 33 thermostats in the building.”

As a result of the new Daikin Applied chiller system, the building’s mechanical systems are more sustainable, resulting in significantly less water and electricity use. Prior to the chiller replacement, the Patterson building’s annual electric bill was approximately $200,000. Now, with the new Magnitude chiller, Roush estimated electrical costs have been reduced by 25 percent. This equates to roughly 355,000 kWh saved per year, or a 162,000-lb reduction of CO2 emissions per year.

The Patterson building is set for a new era as downtown Fresno continues to revitalize. The Fulton Mall is currently undergoing a major renovation, thanks, in part, to federal Transportation Investment Generating Economic Recovery funding, with completion expected by late 2016.

For more information, visit www.DaikinApplied.com. MCAA thanks Daikin Group for being a benefactor of MCAA 2016 and providing beverages for the closing dinner.

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.

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.

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.

ACCO Pairs BIM and Daikin McQuay Chillers for North America’s Greenest Urban Office Building

Commitment to energy-efficient products such as Daikin McQuay’s Magnitude® chillers and reliance on building information modeling (BIM) to manage a complex project helped ACCO Engineered Systems complete what has been called “the greenest urban office building in North America.” The San Francisco Public Utilities Commission (SFPUC) headquarters in downtown San Francisco at 525 Golden Gate opened in July 2012. It produces a 50-percent-smaller carbon footprint and uses 32 percent less energy and 60 percent less water than similar 13-story office buildings.

Complexity Demanded Teamwork

The scope of the SFPUC building project entailed an exacting design and construction process. ACCO Engineered Systems in San Leandro, CA, served as the mechanical contractor on the project. Nial Keeling, P.E., ACCO HVAC project engineer, said the project’s complexity demanded teamwork, so he relied on BIM.

“This was not a standard job,” said Keeling. “The sheer volume of paperwork involved, including owner-directed changes and requests for information, was huge due to the complexity of the systems. Everyone on the team worked well together.”

ACCO met the complex requirements of the SFPUC Headquarters, which includes integrated hybrid solar array and wind turbines, by using BIM and energy-efficient products such as Daikin McQuay chillers.

Solar and wind power, high-efficiency mechanical systems, natural ventilation, and daylight harvesting all contribute to the remarkable energy savings at 525 Golden Gate. The exterior of the building uses roof-mounted solar arrays and wind turbines that can generate up to 7 percent of the building’s energy needs. On the interior, additional shading devices control glare and minimize heat gain while light shelves facilitate daylight harvesting. Lighting and work station equipment shut off automatically after hours.

After factory-certified testing to AHRI Standard 550/590 for water cooled chillers, two Daikin McQuay Magnitude chillers were selected for the building, one 500 tons and one 250 tons. With magnetic bearing compressors and integral variable frequency drives, these chillers are 40 percent more energy-efficient than traditional centrifugal compressor chillers. Their performance allows the building to satisfy varied operating conditions efficiently, especially at part load, which occurs frequently in the mild San Francisco climate.

The SFPUC headquarters houses more than 900 employees and includes a data center in the lower level, a childcare center, and a café. The SFPUC estimates that building and owning its new headquarters will allow the department to save local residents around $3.7 billion ($500 million in 2012 dollars) over the expected 100-year life of the building.

A Traditional Mechanical System With a Modern Twist

The building’s HVAC system design is based on a traditional four-pipe system and includes the two chillers, two rooftop cooling towers for the chilled water system, two large VAV custom air-handling units, heat exchangers, and an underfloor air-distribution system that conserves building space, minimizes ductwork, and allows personal control of airflow.

The building’s underfloor air-distribution system accommodates data lines and most of the ventilation infrastructure, including air-handling equipment as well as linear and swirl diffusers in the floor that supply air for cooling. The building envelope includes operable windows that occupants can control. If a window is opened, the building automation system shuts off the flow of conditioned air through the underfloor system to the corresponding zone.

With all the efficiency measures, the building’s design exceeds ASHRAE 90.1 requirements for energy efficiency for heating and cooling in new office buildings by an impressive 51 percent.

The approximately 10-foot by 30-foot mechanical room is a partial 14th floor where the chillers were installed. “The rigging requirements included setting the chillers in place and anchoring them down based on the seismic data as calculated and signed off by the structural engineers and architect,” said Keeling. “The chillers, which themselves are seismic compliant, had to be anchored to undertake a seismic event and isolate the vibration between the chillers and the building.”

Building Intelligence

From the building elevators to the waste water treatment system to solar and wind systems, a comprehensive Integrated Building Management System monitors and helps to manage approximately 13,500 data points collected from every building system. This system makes all HVAC-related information—including the plumbing and fuel oil system—readily accessible.

Another unique advanced system is an on-site grey- and black-water treatment technology called the Living Machine®, which reclaims and treats all of the waste water from the building to meet the demand for the building’s restrooms. The Living Machine can treat 5,000 gallons of water daily, reducing per-person water use from 12 gallons to five.

Public Enthusiasm

The SFPUC building has generated widespread enthusiasm from San Francisco residents. Public tours of the facility that began in June quickly reached capacity. The SFPUC encourages self-guided tours of the building lobby, where visitors can view the digital arts wall and read about the sustainability and architectural innovations of 525 Golden Gate.

For more information, visit www.daikinmcquay.com.

MCAA thanks Daikin for being a major sponsor of MCAA 2013.

Elliot-Lewis Overcomes Challenges of Historical Renovation with Innovative Carrier Systems

Philadelphia National Landmark Earns LEED Platinum Certification

By opting for Carrier’s geothermal exchange system, Elliot-Lewis helped The Friends Center in central Philadelphia upgrade its heating and cooling plant and earn LEED® Platinum certification, despite the challenges posed by an urban location and national landmark status. The Friends Center campus in central Philadelphia is owned and operated by The Religious Society of Friends, commonly known as the Quakers.

Friends of the Earth

Faced with the need to renovate the heating and cooling plant, the Friends decided to take this opportunity to eliminate their reliance on fossil fuels and secure the future comfort of worshippers, office inhabitants, and the children and staff of the onsite daycare center using 100-percent renewable energy. Environmental integrity, responsible use of resources, and the goal of carbon neutrality were driving forces in the Friends’ decision-making process. In addition, their design solution had to take into account the campus’s location in center-city Philadelphia.

The centerpiece of the $12.5 million Friends Center renovation is a Carrier geothermal exchange system designed to eliminate the property’s reliance on fossil fuels for heating and cooling. Using deep wells installed directly below the Friends Center campus, the new system—which includes Carrier geothermal heat pumps, air handlers, air terminals, fan coil units, hot water coils, and digital controls—enabled the Friends to use geothermal technology despite their metropolitan location, in which the extensive surface water-loop of a typical geothermal system would have been impossible. In addition, the i-Vu® open protocol web-based building automation system was specified, enabling Friends Center staff to monitor and control every aspect of the geothermal system as well as other building functions.

The Friends Center campus includes three buildings: the Race Street Meetinghouse, a national historic landmark built in 1856, and two modern facilities that house office and conference space. The 54,000-square-foot facility is home to 19 nonprofit organizations and a daycare center. It is used by about 300 employees and 75 children each day, plus the congregation of the Central Philadelphia Monthly Meeting. In addition to the goals of eliminating the Center’s dependence on nonrenewable resources and cutting greenhouse gas emissions to zero, the integrity of the Meetinghouse had to be preserved.

Digging Deep

Geothermal technology was identified as the key to the Friends Center’s sustainable future. A traditional geothermal system would have required a well field larger than possible in the middle of Philadelphia. Instead, six deep wells—the first in Pennsylvania—were drilled for the Center’s system. Each well is six inches in diameter and more than 1,500 feet deep. Water from the wells is used to supply the geothermal heat pumps, which provide heating and air conditioning for the Center. Carrier geothermal equipment was chosen to transform the latent energy of the well water into comfort for the inhabitants of the Center.

Jonathan Salemo, project manager for Elliott-Lewis, said, “We chose Carrier because they provided heat pumps and controls that met our requirements in terms of efficiency, capacity, features, and cost. I was very impressed with the operation of the Carrier water-to-water heat pumps and with their ability to operate as both a chiller and a boiler, allowing the system to provide simultaneous heating and cooling.” This ability enables Friends Center staff to manage the comfort of the highly diverse areas of the facility using one integrated system that draws solely on renewable energy.

Minimizing Waste

To avoid wastefully replacing equipment that was still in good working order, the new system was integrated into some existing components. The facility could not use ductwork, so individual water-to-air geothermal heat pumps were used to provide efficient space comfort. In the two newer buildings, Carrier’s Aquazone 50PSW water-to-water heat pumps replaced the existing chiller and city steam system. The existing air handler was improved with a variable speed drive, which increases efficiency and extends equipment life, while the air system was upgraded to variable air volume, another efficiency improvement. Finally, fan coil units were deployed in perimeter spaces to offset heating loads.

Robert Pry, senior controls engineer for Carrier, said, “One of the most significant challenges of the controls design at The Friends Center was the integration of water, air, and ancillary systems. The equipment was connected via the open protocol i-Vu system, which allows staff to observe and control the operation of the HVAC and rainwater collection systems.”

In the end, the careful process of renovating The Friends Center paid off. The Center eliminated its fossil fuel emissions of 326 tons per year and is now positioned for a sustainable future in its center-city location. The Center was rewarded with LEED Platinum certification, indicating that the Friends have obtained their goal of responsible comfort and good stewardship of resources.

For more information, visit www.commercial.carrier.com.

Straus Systems Grows Business with Johnson Controls’ Innovative Technologies

The Central Plant Optimization™ (CPO) software from Johnson Controls that is helping a global marketer and distributor of food service products significantly reduce its central plant energy consumption is also helping Straus Systems of Stafford, TX, advance their position as a leader in the installation of new technologies. “Straus Systems has been in business since 1933, and we continue to build our job resume,” said Vice President of Operations Management Paul Alexander. “Projects like this one that incorporate innovative technologies like CPO30 can help us differentiate our company and grow our business. Our success serves as a springboard to capture new business, particularly among companies interested in best-inclass, energy-saving solutions.”

Transforming an Outdated Building

The client is wrapping up the third phase of a multi-phase renovation that began more than two years ago with the purchase of a 20-plus-year-old former call center facility. The company purchased the 660,000-square-foot structure to create a shared services facility for its North American distribution centers. When completed, the building will house centralized functions, such as customer service, accounts payable, and accounts receivable, and include a 24/7 mission critical data center.

During the first two phases of the renovation, Straus Systems installed three 350-ton air-cooled chillers to help get the data center operational and meet the challenge of transforming an outdated, vacant building into a code-compliant, state-of-the-art facility with built-in redundancy and building automation that protects against data center downtime and ensures the reliability of call center operations.

As phase three of the renovation nears completion, Straus Systems continues to provide HVAC support to the company. According to Alexander, phase-three accomplishments include the installation of two 1,200-ton water-cooled chillers, two two-cell stainless steel cooling towers, and new pumps, as well as a complete upgrade to the central plant control system. When installed and commissioned, the water-cooled chillers will provide primary cooling to the structure, with the air-cooled system assuming backup responsibilities and providing cooling during off hours.

Upgrading and Innovation

Straus updated the original Metasys® building management system from Johnson Controls with the newest version of Metasys to better manage the facility and provide critical redundancy. The new Metasys system will allow building staff to access, report, and use data on how the building is performing, including energy usage and spend by energy type. The system will help reduce energy consumption and costs while maintaining safe, comfortable, and sustainable environments. And because the system uses the latest web-based and wireless technologies, Metasys will ensure compatibility with mobile devices, allowing users to access the information they need anytime, anywhere.

“In this particular case, the Metasys system is also providing important continuity as we complete the water-cooled system changeout, helping to maintain proper chilled water flow throughout all parts of the building,” noted Alexander. The need for redundancy means the central plant displays twice the number of controllers as would ordinarily be required in a non-critical central plant, providing a myriad of backup scenarios that will ensure data center up-time and maintain call center operations.

“My experience with Metasys has demonstrated that it is a great system, tried and true in installations around the globe,” said Alexander. “But just as important as the product and how well it performs is my relationship with the supplier of that product. I have worked with the Johnson Controls rep on a variety of projects for a number of years, and I know him pretty well. So I have faith in what he says and the recommendations he makes. To me, contractor/supplier relationships like this go a long way toward achieving success and bringing value to the products we install and, more importantly, the customers we serve.”

“Added to the more efficient chillers that we’ve installed, [Johnson Controls’] CPO30 should really help the facility shine as a result of energy savings, and the customer is going to be delighted with those same energy savings when they see their utility bills.”

— Straus Systems Vice President of Operations Management Paul Alexander

This solid relationship and his successful track record with Johnson Controls products made it easier for Alexander and his customer to embrace another innovative technology that the renovated facility features—Johnson Controls CPO30 software. It features patented relational control technology to help significantly reduce central plant energy consumption. Algorithms will make continuous real-time automatic adjustments to the central plant based on building load and weather, while web-based dashboards will enable staff to efficiently measure, verify, and manage the building’s performance in real time.

Real-time data are especially important as the company strives for efficiency and works closely with their local utility to take advantage of rebates that reward improvements in energy efficiency. “CPO30 will help them achieve these rebates in two ways,” explained Alexander. “First, and what I’m most excited about, is the fact that the software will significantly improve operating efficiencies of the central plant. Added to the more efficient chillers that we’ve installed, CPO30 should really help the facility shine as a result of energy savings, and the customer is going to be delighted with those same energy savings when they see their utility bills. In addition, CPO30 will help them document these efficiencies and support their rebate application.”

“I look at this facility as the company’s front door—the place where customers gain access to an enormous product line and register their needs,” Alexander said. “If the facility shuts down, the door is locked, access is denied, and eventually, revenue is impacted. The door needs to remain open, and it most likely will, thanks to the combined efforts of Metasys and CPO30.”

For more information about Johnson Controls, visit www.johnsoncontrols.com.

Tips for Choosing the Best Air-Handling Unit for the Job

With lots of air-handling units to choose from, such as YORK® Solution units from Johnson Controls, HVAC contractors have the flexibility to find the best unit for some of the most demanding applications, including hospitals, theaters, schools and universities, government facilities, and office buildings. Contractors can customize the size and components of air-handling units to accommodate a building’s space constraints, performance needs, and budget. Choosing the right unit can make installation simpler and faster, saving you time and money. When selecting air-handling units for a project, consider the following questions:

1. Overall, what should I keep in mind when choosing an air-handling unit?

Consider the needs and requirements of the building or facility, as well as the features, benefits, and installation options of the air-handling unit. A unit specifically designed and manufactured for a certain application ensures speedy installation, reliable operation, and a satisfied customer.

2. Where will the unit be installed?

An air-handling unit in an office building, for example, requires different functionalities and levels of maintenance than one that’s located in a hospital operating room. Air-handling units designed and optimized for particular applications will perform more efficiently in the designated spaces.

3. What functions are required for the customer’s space, and what energy sources are available?

Depending on the application, various components can be added to the air-handling unit to address specific functions, including heating, cooling, filtration, humidification, and energy recovery. In addition, the unit can be designed to accommodate various energy sources to distribute conditioned air in the most cost-efficient way possible.

4. What size must the air-handler unit be for the customer’s application?

For the greatest degree of flexibility and ease on the jobsite, choose an air-handling unit that can handle the project’s architectural, mechanical room, and space constraints. If you use building information modeling (BIM), find out whether the manufacturer offers unit-specific digital models so designers can confirm in advance that the air handler will accurately fit the space.

5. Is the unit easy to install?

An efficient, smooth installation ensures that the job gets done on time without incurring any additional costs. Should the unit arrive at the jobsite in one piece, or should it be assembled onsite? If it will be assembled onsite, is it easy to put together?

6. Does the unit simplify the coordination of the controls’ installation?

Air-handling units with integrated controls that are tested and packaged at the factory eliminate the need for additional programming and extra hassle that contractors can sometimes encounter during installation. Available controls include intuitive sensors that measure the temperature, humidity, and service status; key diagnostics to measure the efficiency of the various components of the system; actuators that drive dampers and other components; and motors that control the fans and adjust fan speed to whatever the application requires.

7. What kind of installation, maintenance, and service support are available?

Besides the features and benefits of the air-handling units, consider the expertise and service that the manufacturer provides. Will you require assistance when installing the product? How does the manufacturer handle requests for additional parts or service?

8. How will the right air-handling unit help me as a contractor?

The ideal air-handling unit will be cost-efficient and reliable for both you and your customer. It will be designed and manufactured specifically for your customer’s application. Factory-installed and tested controls and a flexible configuration will simplify installation and offer reliability and efficiency for your customer.

Rob Tanner and Kevin Weaver of Johnson Controls® provided the information for this story. For additional information about YORK Solution air-handling units by Johnson Controls, please visit www.johnsoncontrols.com.

MCAA thanks Johnson Controls for being a benefactor of MCAA 2012 and for sponsoring the opening breakfast.