HPAC - Boiler RM Assesment

SEPTEMBER 2015 | www.hpac.
com
Minimizing Ammonia Charge

in Industrial Refrigeration
Systems, Part 2
What Owners Need to Know
About ... Tankless Water Heaters
News & Notes:
Plumbing-Piping Cost Study
Design Solutions:
Combined Heat and Power
•Proper Procedure for a Boiler-Room Assessment

•Hot-Water- and Steam-Boiler Water Treatment
•EPAʼs Ozone Decision
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Circle 152
INSIDE HPAC ENGINEERING
SEPTEMBER 2015 • VOL. 87, NO. 9
PUBLISHING OFFICES:
1100 Superior Ave.
8th Floor
FEATURES:
Cleveland, OH 44114 MANUFACTURING AND INDUSTRIAL
216-696-7000
Fax: 216-696-3432 18 Minimizing Ammonia Charge in Industrial
www.hpac.com
Refrigeration Systems, Part 2 of 2
LINDA REINHARD Last month, Part 1 of this article provided an overview of two new and
Vice President and Market Leader emerging alternatives to conventional pumped-recirculated-liquid
ROBERT MADER systems with the potential to significantly reduce ammonia- (NH3-)
Editorial Director refrigerant charge: advanced direct-expansion (also known as dry
312-840-8404 expansion or DX) systems utilizing electronic expansion valves and
robert.mader@penton.com carbon-dioxide (CO2)/NH3 cascade systems. This month, the article
SCOTT ARNOLD concludes with discussion of CO2/NH3-with-pumped-volatile-brine
Executive Editor systems, a line of air- and water-cooled NH3 packaged chillers and a
216-931-9980
scott.arnold@penton.com line of air-cooled condensing units, and a line of self-contained
refrigeration systems.
ASHLEY M. DOLES
Content Design Specialist By Terry L. Chapp, PE
JOHN CARROLL SCHOOLS AND UNIVERSITIES/HOSPITALS AND HEALTH CARE/COMMERCIAL OFFICE BUILDINGS/
Advertising Production Coordinator GOVERNMENT BUILDINGS
SONJA CHEADLE
Audience Development Manager 26 What Owners Need to Know About ...
ANGIE GATES Tankless Water Heaters
Group Digital Director This article discusses cost, space, and safety benefits of tankless water
heaters.
SALES OFFICES: By Kunal Shah
DIRECTOR OF SALES/NORTHEAST/
MIDWEST
MIKE HELLMANN
978-289-0098 • Fax: 913-514-6921 SPECIAL SECTION:
mike.hellmann@penton.com
31 Boiler Systems Engineering
NORTH CENTRAL/NEW ENGLAND/ BSE1 Proper Procedure for a Boiler-Room Assessment
SOUTHEAST BSE6 Hot-Water- and Steam-Boiler Water Treatment
JOE DAHLHEIMER
330-289-0269 • Fax: 913-514-6481 BSE12 News & Analysis: Industrial Boiler Operators Bracing for
joe.dahlheimer@penton.com Ozone Decision
BSE16 Product Spotlight
CALIFORNIA/TEXAS
RANDY JETER
512-263-7280 • Fax: 913-514-6628
randle.jeter@penton.com
News & Notes ................................ 4 Classifieds .................................. 47
CLASSIFIEDS/ANCILLARY Design Solutions .......................... 10 Ad Index ...................................... 48
DAVID G. KENNEY
216-931-9725 • Fax: 913-514-6663 New Products .............................. 16
david.kenney@penton.com
DAVID KIESELSTEIN
WEB WORTHY
Chief Executive Officer
Adventures of Johnny Tundra, Cold-Weather Engineer: ‘Capitol Case’
ISSN 1527-4055 On the eve of public hearings at the state capitol,
HPAC Heating/Piping/Air Conditioning Engineering Supervisor of Facilities Maintenance and Operations Hank
is published monthly by Penton Media Inc., 9800
Metcalf Ave., Overland Park, KS 66212-2216. Peri- Hoovestahl is facing a grilling worse than that of any witness:
odicals Postage Paid at Kansas City, MO and at addi- If he does not get the chiller serving the meeting rooms in
tional mailing offices. Canadian Post Publications Mail
agreement No. 40612608. Canada return address: IMEX the recently remodeled building running by noon the next
Global Solutions, P.O. Box 25542, London, ON N6C 6B2. day, Senate Majority Leader—and armchair engineer—
POSTMASTER: Send address changes to Customer Lester Heapleach vows to, shall we say, remove him from office. Luckily for Hank, he has
Service, HPAC Engineering, P.O. Box 2100, Skokie, IL
60076-7800. Member of American Business Press Inc. the backing of his pal Johnny Tundra: http://bit.ly/JT_03.
and Business Publications Audit of Circulation Inc.
ARTICLE REPRINTS and E-PRINTS: Increase Archived Webinar: ‘Improving HVAC Energy Efficiency Through Accurate
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reprints and e-prints are available by contacting HPAC Engineering’s Aug. 11 webinar with Vaisala is now available for viewing on
Wright’s Media at 877-652-5295, e-mail: penton@
wrightsmedia.com, Website: www.wrightsmedia.com. demand. Go to http://bit.ly/Vaisala_0815.
SEPTEMBER 2015 HPAC ENGINEERING 3

FROM THE FIELD NEWS & NOTES
UV-Treatment Pioneer Dies IN BRIEF

USGBC Names Incoming CEO
F
orrest B. Fencl, pioneer of the courageous no matter the pressures
modern application of ultra- to do otherwise.” The U.S. Green Building
violet germicidal irradiation Fencl was a lifelong inventor who Council (USGBC) recently
(UV-C) in HVACR equipment, died wrote or co-wrote 17 patents related announced Chief Operating
at his home in Huntington Beach, to ultraviolet air and surface treat- Officer (COO) Mahesh
Calif., Aug. 1 after a battle with ment. He also was an enthusiastic Ramanujam will move into the
cancer. He was 72 years old. educator and prolific writer, author- role of chief executive officer
Following a ing more than a hundred articles (CEO) when current CEO Rick
distinguished 25- and papers on UV-C. Fedrizzi steps down at the end of
year career at Farr He served ASHRAE throughout 2016.
Co. (now the Cam- his career, including 10 years as a Ramanujam joined the USGBC
fil Group), Fencl Distinguished Lecturer and, later, in 2009 as senior vice president,
founded two com- as a voting member of Technical technology, before being named
panies that pro- Committee 2.9, Ultraviolet Air and COO in September 2011. In
vide surface and Surface Treatment. Also, he co- December 2012, he took on the
airborne microbial Fencl authored the association’s 2008, additional role of president of
control and organic- 2011, 2012, and 2015 Handbook the Green Building Certification
materials decontamination: Steril- chapters on the application of UV-C Institute, now Green Business
Aire, which he served as president technology in HVACR systems. Certification Inc.
and chief executive officer (CEO) Among other contributions, he
from 1995 to 2002, and UV Re- fathered the Two-Step Design Little Red Schoolhouse
sources, which he served as CEO Guide, an engineering tool for Q3 Schedule Announced
from 2005 to 2015. utilizing ASHRAE Standard 62- Xylem Inc.’s Bell & Gossett
“Forrest was a tremendous 1989. brand recently announced the
leader, great friend, and mentor to In 2010, Fencl was named a 2015 third-quarter schedule of
me and so many others,” Dan Jones, Lifetime Fellow by ASHRAE, a systems-design training seminars
president and co-founder of UV distinction recognizing outstanding for engineers, wholesalers, and
Resources, said. “He was a man of contributions to industry research, contractors in the plumbing and
exceptional character and integrity education, or engineering. hydronic heating and cooling
who would do what was right and Continued on Page 8 industries held at its Little Red
Schoolhouse learning center in
Hurst Boiler Founder Dies Morton Grove, Ill.: Design & Ap-
plication of Water Based HVAC
Systems, Sept. 28-30; Service
C
lifton Eugene “Gene” Hurst, 314,000-sq-ft manufacturing facility
founder of Hurst Boiler & on 17 acres. & Maintenance of Water Based
Welding Co., died July 22 at Forty-eight years after its found- HVAC Systems, Oct. 5-7; Modern
the age of 79. ing, the company, the largest Hydronic Heating Systems-Basic,
Hurst and his employer in the Coolidge area, Oct. 12-14; Modern Hydronic
wife, Edna, started with more than 350 employees at Heating Systems-Advanced, Oct.
the business in a full production capacity, remains 19-21; Design & Application of
shop behind their in the family. Currently, it is under Water Based HVAC Systems,
home in Thomas- the direction of the Hurst children: Nov. 9-11; Large Chilled Water
ville, Ga., in 1967. Tommy, Hayward, Teri, and Jeff. System Design, Nov. 16-18; and
Three years later, “Anyone who knew him, in what- Steam System Design & Applica-
they moved the com- ever capacity, would certainly agree tion, Dec. 7-9.
pany to its present Hurst he was a kind, humble, and inspiring Seminar reservations must be
location in Coolidge, individual who cared deeply for his made through a Bell & Gossett
Ga., where it manufactures a full family and the people who worked representative. For more informa-
line of solid-waste, wood, gas, coal, for him,” Jeff Hurst, Hurst Boiler’s tion, go to www.bellgossett.com/
and oil-fired steam and hot-water director of marketing, said of his training-education.
boilers and related equipment in a father.
4 HPAC ENGINEERING SEPTEMBER 2015

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Circle 153
Uponor Studies Pipe Material, Labor Costs

U
QPOPS QSPWJEFSPGDSPTT
MJOLFEQPMZFUIZMFOF 1&9

QMVNCJOH JOEPPSDMJNBUF
BOE GJSFTBGFUZ TZTUFNT GPS SFTJ
EFOUJBMBOEDPNNFSDJBMCVJMEJOHT
SFDFOUMZDPNQMFUFEBTUVEZDPN
QBSJOH UIF DPTUFGGFDUJWFOFTT PG
GJWFUZQFTPGQMVNCJOHQJQJOHGPS
BNVMUJGBNJMZCVJMEJOH
.BUFSJBMBOEMBCPSDPTUTXFSF
EFUFSNJOFEGPSUIFGPMMPXJOHTZTUFN
UZQFT
t1&9
t$IMPSJOBUFEQPMZWJOZMDIMPSJEF
$17$
USVOLBOECSBODI
t$PQQFSQSFTTUSVOLBOECSBODI
t$PQQFSTXFBUUSVOLBOECSBODI
t1PMZQSPQZMFOF 113
USVOLBOE FIGURES 1 and 2. Risers for PEX units (left) and CPVC, copper, and PP-R trunk and
CSBODI branch units (right).
5IFCVJMEJOHXBTB TRGU
VOJUNVMUJGBNJMZTUSVDUVSFXJUI with cable ties (except in units). t$BQTBUGJYUVSFUFSNJOBUJPOT
UISFFEXFMMJOHMFWFMTPWFSBPOF tUPJO"45.'FMCPXT GPSMBWBUPSJFT XBUFSDMPTFUT BOE
MFWFMQBSLJOHHBSBHF t
UPJO"45.'DPN TJOLT
5IFEFTJHOIBEUIFNBJODPMEXB NFSDJBMCBMMWBMWFT t#PYFTGPSJDFNBLFSTBOEXBTI
UFSEJTUSJCVUJPOSPVUFEJOUIFQBSL t4XFBUBEBQUFSTUPUSBOTJUJPOUP JOHNBDIJOFT
JOHHBSBHFBOEUIFNBJOIPUXBUFS MBSHFSEJBNFUFSDPQQFSQJQF Copper sweat
EJTUSJCVUJPOSPVUFEJOUIFUIJSEGMPPS t&OHJOFFSFEQPMZNFSNVMUJQPSU t
UP JO 5ZQF - QJQF BOE
DFJMJOH XJUISJTFSTUSBOTQPSUJOHXB tees. GJUUJOHT
UFSVQUPUIFGPVSUIGMPPSBOEEPXO t1MVHTBUGJYUVSFUFSNJOBUJPOTGPS t
UPJOFMCPXT
UPUIFTFDPOEGMPPS GJHVSFTBOE
MBWBUPSJFT XBUFSDMPTFUT BOETJOLT t
UPJODPNNFSDJBMTXFBU
"MUIPVHIUIFQSPKFDUDBMMFEGPS t"45.'PVUMFUCPYFTGPSJDF CBMMWBMWFT
QJQFBOEGJUUJOHTMBSHFSUIBOJO UIF NBLFSTBOEXBTIJOHNBDIJOFT t$BQTBUGJYUVSFUFSNJOBUJPOTGPS
TUVEZMPPLFEPOMZBUDPTUTGPSQJQF CPVC MBWBUPSJFT XBUFSDMPTFUT BOETJOLT
GJUUJOHT BOEWBMWFTJOBOETNBMMFS t
UP JO QJQF BOE GJUUJOHT t#PYFTGPSJDFNBLFSTBOEXBTI
.BUFSJBMDPTUTXFSFDBMDVMBUFE 4%3$54
JOHNBDIJOFT
BUUSBEFQSJDJOHWBMVFTGSPN t
UPJOFMCPXT PP-R
BDSPTTUIF6OJUFE4UBUFT t4PMWFOUDFNFOUGJUUJOHT t
UPJOQJQFBOEGJUUJOHT XJUI
t
UP JO DPNNFSDJBM CBMM BTUBOEBSEEJNFOTJPOSBUJP 4%3

Materials WBMWFTXJUIUISFBEFEBEBQUFST PGGPSDPMEXBUFSQJQFBOEB4%3
'PSFBDITZTUFNUZQF UIFGPMMPX t$BQTBUGJYUVSFUFSNJOBUJPOTGPS PGNVMUJMBZFS .'
GPSIPUXBUFS
JOHNBUFSJBMTXFSFJODMVEFEJOUIF MBWBUPSJFT XBUFSDMPTFUT BOETJOLT pipe.
QSPKFDUDPTUT t#PYFTGPSJDFNBLFSTBOEXBTI t
UPJOFMCPXT
PEX JOHNBDIJOFT t4PDLFUUZQFGJUUJOHT
t
UPJO&OHFMPSQFSPYJEF Copper press t
UP JO DPNNFSDJBM CBMM
NFUIPE 1&9B
QJQF BOE "45. t
UPJO5ZQF-QJQFBOEQSFTT WBMWFTXJUIUISFBEFEBEBQUFST
' Standard Specification for GJUUJOHT t$BQTBUGJYUVSFUFSNJOBUJPOTGPS
Cold Expansion Fittings With PEX t
UPJOQSFTTFMCPXT MBWBUPSJFT XBUFSDMPTFUT BOETJOLT
Reinforcing Rings for Use With t
UPJODPNNFSDJBMQSFTTCBMM t#PYFTGPSJDFNBLFSTBOEXBTI
Cross-linked Polyethylene (PEX) WBMWFT JOHNBDIJOFT
Tubing GJUUJOHT
tUPJOQJQFTVQQPSUDIBOOFM

FrOm tHe FIeLD NeWS & NOteS COTTONWOOD
STOP FOULING OF CONDENSER COILS/COOLING TOWERS & AIR HANDLERS

FILTER SCREENS™
Keep Equipment Clean All Season
Labor Study Results Long & Simplify Maintenance
Labor was calculated using the Material and labor costs were
Mechanical Contractors Association determined by building section:
of America (MCAA) component- • Main piping, which included all
method approach. According to pipe and fittings 2 in. and smaller
MCAA: “The component method that were part of the horizontal
is based on the use of labor units cold-water distribution system on
that represent all activities neces- the garage level and the hot-water
sary for the installation of one system on the third level.
component (such as a 90-degree • Unit piping, which included all
elbow or a tee). For piping, the pipe and fittings within units after
unit is in man-hours per foot, and the riser branch. Unit costs included
for components such as fittings, hot- and cold-water isolation valves.
the unit is represented by each. Fixture terminations were plugged Amazingly
A labor unit is expressed in terms or capped for rough-in. Easy to Clean
of man-hours to install a unit of • Riser piping, which included
material (such as a foot of pipe), an all vertical piping and fittings. For
individual item (such as a fitting or cold-water risers, the piping started
valve), or perform a specific task in the parking garage and rose
(such as welding a joint).” roughly 30 ft to the fourth floor. For
In developing the labor units, hot-water risers, the piping started Quick Release Fasteners For Every Applications
MCAA reviewed many aspects of in the third-floor ceiling space and
installation, including: was distributed 10 ft up to the fourth
• Receiving. floor and 10 ft down to the second
• Unloading. floor. Riser costs included isolation
• Stockpiling. valves at the base.
• Distribution. Table 1 shows estimated labor
• Handling and erection. hours for the individual building
• Fitting and joining. sections.
• Pressure testing. Table 2 shows the total project
Labor costs were calculated cost. BENEFITS:
• Increases AHU Filter Service Life up to 60%
using a rate of $75 per hour, based
• Reduce Condenser Coil Cleaning time & effort up to 70%
on extensive research of labor Individual-Unit Comparison • Reduce Cooling Tower Maintenance up to 70% and Chemical
rates across the United States. Material and labor costs were Treatment Cost up to 50%
• Reduce Energy Cost up to 30%
• Re-useable - Service Life up to 15+ yrs (varies by filter grade)
FEATURES:
• Compatible with all air cooled chillers, RTU’s, AHU’s, louvers, cooling
towers and more.
• Quick Release Fasteners
• Filter Grades for Every Budget & Application
• Exceptionally low static pressure - nearly invisible to air-flow
• Non-stick surface - cleans easily by rain,
TABLE 1. Labor hours by building section. broom, brush, garden hose or shop vac.
• Resists UV, Mold, Mildew and Flame
• Tear & Puncture Resistant - Rip Stop Feature
• Available with Hail Guard Feature
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TABLE 2. Total project cost (U.S. dollars) by building section. Circle 154
September 2015 HPAC EnginEEring 7
CODES & STANDARDS

ASHRAE/NEMA
Proposed ASHRAE/NEMA
Standard 201P, Facility Smart
Grid Information Model, will be
open for public review until
Oct. 6, 2015.
ASHRAE/NEMA Standard 201P
defines an object-oriented
information model to enable
appliances and control systems
in homes, buildings, and
FIGURES 3 and 4. Individual-unit PEX design (left) and CPVC, copper, and PP-R trunk and industrial facilities to manage
branch design (right). electrical loads and generation
sources in response to communi-
broken down at an individual-unit ual riser is shown in Table 5. Table cation with a smart electrical grid
level. Figures 3 and 4 show unit pip- 6 shows the total costs of piping a and to communicate information
ing. Table 3 shows the labor hours riser. about those electrical loads to
utility and other electrical-service
This report was prepared by providers.
Daniel Worm, plumbing-product To read the draft standard and
specialist for Uponor. Worm has to submit comments, visit
TABLE 3. Individual-unit labor hours. more than 14 years of plumbing- www.ashrae.org/publicreviews.
Continued from Page 4

Fencl also had close working rela-
tionships with The National Institute
for Occupational Safety and Health
and NASA.
TABLE 4. Total individual-unit cost. “Forrest consulted with NASA
scientists and engineers on the
required to pipe a unit. Table 4 industry experience, with an development of the first solid-state
shows the total costs of piping a unit. emphasis on application and UV-C decontamination system to
design. He is a licensed building be operated on a manned space
Individual-Riser Comparison contractor, a certified plumbing vehicle,” Jim Good, a senior system
The labor required for an individ- designer, and a member of the engineer with aerospace and engi-
American Society of Plumbing neering contractor Teledyne Brown
Engineers. He holds a degree in Engineering, said. “This system has
architectural design and drafting. been operating on board the Inter-
He can be reached at daniel.worm national Space Station since June of
TABLE 5. Individual-riser labor hours. @uponor.com. 2014, providing significant enhance-
ments to science operations and
protecting the crew from biohaz-
ards in biological samples. His most
recent collaboration was helping
develop an earth-based system to
revolutionize microbial inactivation
in large medical and office facilities.”
TABLE 6. Total individual-riser cost. Before beginning his corporate
career, Fencl served as an electron-
ics technician in the U.S. Navy.

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Circle 155
FrOm tHe FIeLD DeSIGN SOLUtIONS
Ronald McDonald House in NYC Wipes out three more years, which is very
impressive.”
Mechanical Slate Clean, Installs CHP In New York City, adoption of
CHP technology is up nearly 400
Condensing boilers provide double redundancy percent over the last decade. Cafer
said Hurricane Sandy in 2012 stirred
S
ince 1974, Ronald McDonald would be right for Ronald McDon- great interest in cogeneration; while
Houses have been serving ald House New York. much of the grid was down, several
families of seriously ill or “All applications are different, buildings he and Beyer worked in
injured children receiving treatment based on energy-use trends and continued operating as usual, cour-
far from home, providing lodging, the physical structures themselves,” tesy of well-designed CHP systems.
meals, and more at little or some- Cafer explained. “We took a holistic “Cogen has always made sense,”
times no cost. Today, there are 322 approach; energy models were Cafer said. “But with cheap natural
Ronald McDonald Houses in 57 developed based on past use and gas, costly power, and an overtaxed
countries, the largest being Ronald projected costs.” electric grid in NYC, it makes more
McDonald House New York. sense now than ever.”
Located on Manhattan’s
Upper East Side, the 13-story, Hardware
70,000-sq-ft brick building Integrated HVAC
provides temporary hous- Systems and Services
ing to as many as 84 families. installed a natural-gas-
Though its living spaces are fired CHP unit from
modern, the systems serving IntelliGen Power Systems
them dated to the facility’s on the roof. The pre-
opening in 1989. packaged unit combines
“The boiler and chillers a roughly 600-hp, 12-
were past their life cycle,” Ike cylinder reciprocating
Beyer, owner of Integrated engine with a 250-kW
HVAC Systems and Services The mechanical room inside of Ronald McDonald House New generator to produce
Inc., said. “As a non-profit York. power for the building.
organization, the project’s Heat from the engine—up
payback and sustainability were The study was funded in part by to 1.5 million Btu under full load—is
equally important as the initial cost.” New York State Energy Research rejected into a large plate-and-frame
Beyer worked with Chris Cafer, a n d D e v e l o p m e n t A u t h o r i t y heat exchanger, isolating the CHP-
associate and senior mechanical (NYSERDA). unit loop from the building’s various
engineer for Energy Concepts En- After two years of research and needs for heat.
gineering, to design and install new data collection, on-site cogeneration Three loads draw from the heat
systems at Ronald McDonald House equipment was determined capable exchanger: DHW production, the
New York. Their firms’ decades of of meeting the building’s heating, building’s two-pipe fan-coil unit in
experience would lead to a solution cooling, and domestic-hot-water heating mode, and three new 50-
surpassing facility managers’ expec- (DHW) needs while supplying 95 ton absorption chillers from Yazaki
tations of comfort and sustainability. percent of its power. Energy Systems on the 12th floor.
At every step of the renovation, “Making the changes necessary “Absorption chillers are the
Mel Farrell, BSEE, chief engineer to convert to a CHP system would nearest thing to a magic box,” Cafer
for Ronald McDonald House New have yielded a seven- or eight-year said. “You put hot water in and get
York, was intimately involved. payback,” Cafer said. “But the char- chilled water out.”
ity wanted to make huge strides The chillers’ lithium-bromide
“If” Before “How” toward sustainability, occupant absorption technology lends itself
In 2011, long before any plans for comfort, and cost avoidance, so the well to CHP applications.
a retrofit were drawn up, Energy decision was made to remove nearly During the shoulder seasons,
Concepts Engineering began a all old mechanical components and the CHP unit has the potential to
study to determine if combined heat start with a clean slate. This only produce more thermal energy than
and power (CHP), or cogeneration, pushed the retrofit’s simple payback the facility needs. In the event of
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excess heat, a dry cooler on the roof together, each modulating to the structure was updated with LED
provides heat rejection. roughly 50 percent to meet design fixtures, a joint project between
“Being that the absorption chillers load. Integrated HVAC Systems and
are now the only source of cooled “The contribution of the boilers in Services and Innovative Energy
water, both the heating and cooling this situation is critical, even more Solutions Group and partially
elements in the building are entirely so than in a conventional heating funded by NYSERDA.
dependent on a source of hot water,” application,” Don Rathe, president Work began in December 2013.
Beyer said. “During maintenance of of manufacturers’ representative
the CHP unit or in the unlikely event Rathe Associates, said. “In addition Maintaining Operation
of failure, we needed complete re- to carrying the heating and snow- During the renovation, Beyer
dundancy in the form of condensing melt loads, the cooling system would said, “Patients and families still
boilers. This is the case with almost also go down if the boilers failed to needed a place to stay, and the need
every cogen application.” run.” to maintain a clean, quiet building ...
A pair of Laars NeoTherm con- Integrated HVAC Systems and rose above all else.”
densing boilers provides double Services replaced the building’s With all rooms full, Beyer, Cafer,
redundancy. The 1.7-MMBtu larger DHW equipment with two 85-gal. and Farrell faced the monumental
boiler more than matches the output instantaneous, indirect-fired water task of renovating three systems
of the CHP unit; it alone is able to heaters. A new building automa- without displacing occupants from
condition the building, regardless tion system simplifies the otherwise a single room or letting comfort
of the season. The 1-MMBtu smaller complex systems, while a snowmelt levels drop. Their second greatest
boiler is in place for further peace zone outside keeps guests safe and challenge was working within small
of mind. If the CHP unit is turned eliminates costly winter sidewalk mechanical spaces.
off for any reason, the boilers fire maintenance. Lighting throughout “Because the project started in
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Circle 157
Circle 158
heating season, we began to de- Control and Comfort existing two-pipe fan coils with a
molish the old chillers on the 12th Over the summer, 2,200 sq ft of four-pipe system,” Beyer said. “It’s
floor while the existing boilers in the sidewalks and approach in front more than just an energy consider-
basement remained online,” Beyer of the main entrance was removed ation; it offers precise control for
said. “Meanwhile, the CHP unit, new and repoured, but not before PEX optimal comfort. The kids staying
boilers, and chillers were all rigged was tied down to provide a snow- here are going through chemo and
to the roof at one time.” melt solution. For this portion of the radiation therapy. Some might feel
The CHP unit and absorption project, Rathe Associates donated hot while others are shivering. A
chillers were installed in time for materials, while Integrated HVAC four-pipe system will allow us to
cooling season, at which point the Systems and Services donated labor. provide heat to one room and air
old boilers were broken down and In the lobby, visitors can interact conditioning to the next.”
hauled out. The downstairs boiler with a screen showing all of the “Every part of this project has
room then became a pump room, mechanical components and how come together perfectly,” Farrell
supplying almost all circulation for they interact to meet the building’s said. “... This renovation means that
the structure. All heat exchangers energy needs. The screen also shows for many years to come, the NYC
and DHW production equipment energy use and production in real facility is going to continue serv-
are located there as well. time, courtesy of a full BACnet con- ing families in some of their darkest
“Farrell wanted the very best trol system from Reliable Controls. hours.”
equipment money could buy; The new controls are necessary for
efficiency and dependability were the final phase of the retrofit, which Information and photograph courtesy
his key concern,” Cafer said. “Ike is in the planning stages and slated of John Vastyan, president of Common
and I had to figure out how to make to begin later this year. Ground, a trade-communications firm
it all fit.” “We’re looking to replace the based in Manheim, Pa.
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Circle 161
MINIMIZING NA/PHOTOS.COM>>
AMMONIA CHARGE IN
INDUSTRIAL REFRIGERATION SYSTEMS,
Part 2 of 2
A review of five alternatives to conventional pumped-recirculated-liquid systems
By TERRY L. CHAPP, PE categorized as hybrid systems, meaning they are used

Danfoss Industrial Refrigeration to confine NH3 charge to the machine room and use a
Baltimore, Md. secondary coolant in cold rooms.
This month, the article concludes with discussion
Editor’s note: This article, Part 1 (http://bit.ly/ of another hybrid system—CO 2 /NH 3 with pumped
Chapp1_0815) of which was published in the August 2015 volatile brine (PVB)—and two examples of packaged—
issue of HPAC Engineering, is adapted from the white meaning they eliminate interconnecting piping and
paper “Low Ammonia Charge Refrigeration Systems for corresponding NH3 inventory with numerous smaller,
Cold Storage,” published by the International Association self-contained systems—systems:
of Refrigerated Warehouses and the International • A line of air- and water-cooled NH 3 packaged
L
Association for Cold Storage Construction. To read and chillers and a line of air-cooled condensing units.
download the full paper, go to http://bit.ly/NH3_paper. • A line of self-contained refrigeration systems.
Last month, Part 1 of this article provided an overview Hybrid Systems (continued)
of two of five new and emerging alternatives to conven- CO2/NH3 with PVB. A CO2/NH3-with-PVB system has
tional pumped-recirculated-liquid (PRL) systems with much in common with a CO2/NH3 cascade system. In this
the potential to significantly reduce ammonia- (NH 3-) system, however, there is no primary CO2 compressor. It
refrigerant charges: is possible there may be a small CO2 compressor for hot-
• Advanced direct-expansion (also known as dry gas defrost, but there are other options that allow for
expansion or DX) systems utilizing electronic expansion defrost without the addition of a compressor. To many,
valves, categorized as central systems, meaning they this can be described as a chiller system. Most chiller
are used to minimize or eliminate unused NH3 charge. systems, however, use water or some formulation of
• Carbon-dioxide (CO 2 )/NH 3 cascade systems, glycol/water, and the cooling coil is not an evaporator,
National business-development manager for Danfoss Industrial Refrigeration, Terry L. Chapp, PE, has been involved in all
aspects of HVACR, with particular emphasis on heat exchangers, valves, and controls, over the last 35 years. He is a member
of The American Society of Mechanical Engineers, ASHRAE, the International Institute of Ammonia Refrigeration (IIAR), and
the Refrigerating Engineers and Technicians Association. He serves on the safety committee of IIAR and the refrigeration and
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Circle 162
minimizing AmmoniA ChArge in induStriAl refrigerAtion SyStemS, pArt 2 of 2
but, rather, just a sensible-heat exchanger. This has

an enormous impact on not only the amount of heat-
transfer fluid required to meet the cooling load, but
on pump size, pumping power, piping size, and heat-
exchanger size. Compared with a traditional chiller
system, a CO2/NH3-with-PVB system has higher energy
efficiency and, usually, a lower installed cost. Actual data
for industrial refrigeration systems is scarce; in simi-
lar systems for commercial refrigeration, the pumping
power required to circulate CO2 as a volatile secondary
refrigerant has been found to represent about 5 percent
of the power that would be required to circulate a non-
volatile secondary refrigerant, such as water or glycol.4
CO 2 systems typically operate between 83 psi and
507 psi. What that means is the piping always is under
pressure, and the ability for water or air to be drawn
into the system is virtually non-existent.
Figure 3 shows a system in which liquid CO2 is cooled
to a temperature low enough to satisfy the cooling loads
in the freezers. The liquid is cooled to the required tem-
perature in the cascade heat exchanger and then stored
in the CO 2 recirculator vessel. This same refrigerant
then is used to satisfy the cooling loads of the coolers. FIGURE 3. CO2/NH3 with PVB.
The key component in meeting the cooler requirements
is the pulse-width modulating valve, which is used and only a modestly sized receiver.
simply as a metering device to supply enough refriger- Although it is believed actual NH3 refrigerant charge
ant to meet the load requirements of the coolers. The could be as low as 2.5 lb per ton of refrigeration (TR),
intention is not to evaporate all of the refrigerant, but, there is little data to support this. For the purposes
rather, simply to satisfy the room temperature setting. of this article, the system’s NH3 charge will be assumed
This approach was chosen for the hypothetical to be the same as that of the CO2/NH3 cascade system, or
facility in this study because of the high ratio of freezer 6 lb per TR.
load to cooler load. Because there is no compressor One of the main features of CO 2 is its high heat-
and no suction accumulator, no effort is made to ensure transfer coefficient, which leads to smaller temperature
liquid is not carried out of the evaporators. The main differences in both evaporators and cascade heat
driver is the temperature at which coolers typically exchangers. Additionally, pumping power requirements
operate. If the cooler is set at, say, 55˚F, and the evapora- are low for CO2. The result is system efficiency close to
tor has been designed for a 10˚F temperature difference, that of a PRL system.
the CO2 would be operating at nearly 600 psig. While The use of CO2 volatile brine is not new, but has had
this is not an unmanageable number, it does push some limited deployment in cold-storage applications. For the
of the equipment (especially the pump) to its limit. purposes of this article, the CO2/NH3-with-PVB system
The special considerations for CO 2/NH 3 with PVB will be assumed to be only slightly more energy-
are nearly the same as those for CO2/NH3 cascade (see intensive than the baseline system. This assumption is
Part 1), except oil is not required for the system. based on a generalized view of the “energy consumers”
For blast freezing, the temperature of the NH3 avail- in the system and how they would be expected to
able to condense CO2 liquid as low as -50˚F needs to be compare to an equivalently sized baseline system. The
on the order of -60˚F. For all practical purposes, this value that will be used in this article is 2.5 KW per TR.
requires a two-stage refrigeration system for the NH3. The installed cost of the system likely will be very close
At first glance, it might appear the charge will be quite to or slightly higher than that of a CO 2/NH 3 cascade
high because of the two compressors, an intercooler system. The NH3 refrigeration system will be larger and
(optional), and a heat exchanger large enough to satisfy more costly, but there are no CO2 compressors, unless
the entire load of the cold-storage facility. Keep in mind, hot gas is the desired route for defrost. The cascade
however, that there is minimal piping, no evaporators heat exchanger will be larger for the CO2/NH3-with-PVB
(other than the cascade heat exchanger), a condenser, system, but there will be no need for an oil still. With

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this in mind, a conservative estimate for the cost of the

system is $7,400 per TR.
Regarding maintenance cost, because all of the NH3
is confined to the machine room, oil sumps are very
manageable, and oil draining is limited to a significantly
reduced number of vessels. Because the volatile-brine
system has no requirements for oil, there is no oil-
draining requirement.
On the additional-cost side of the equation, filter
dryers must be monitored and maintained on a routine
basis. Also, a backup condensing unit is highly recom-
mended for periods of “standstill.” This system also must
be maintained routinely to ensure it is in good working
order when and if it is needed.
The overall conclusion regarding maintenance costs
is that any increase in cost over that of a conventional
PRL system will be minimal.
Packaged Systems
Air- and water-cooled NH 3 packaged chiller and air-
cooled condensing unit. A UK manufacturer offers a
line of packaged systems offering a number of basic
advantages, including:
• No need for a machine room. FIGURE 4. Air- and water-cooled NH3 packaged chiller and air-
• Avoidance of a large-scale vessel for holding NH3 cooled condensing unit.
charge.
• Minimization of distribution piping throughout a typical PRL industrial refrigeration system.
facility. The chiller utilizes NH3 as the primary refrigerant in
The chiller (Figure 4) exhibits a key feature of hybrid “chilling” a secondary heat-transfer fluid for medium-
systems in providing refrigeration to coolers and docks temperature rooms in a cold-storage facility. The
itself. The overall impact is a dramatically reduced NH3 secondary heat-transfer fluid usually is glycol. As seen
charge, with no NH3 present in the rooms being cooled in Figure 4, the glycol is cooled with a plate exchanger
by the chiller. The downside is a negative impact on in the package and then distributed to docks and coolers
system efficiency as a result of the extra heat exchanger as required. The condensers may be air-cooled or water-
(the chiller) and the subsequent inefficiencies of pump- cooled. The manufacturer has developed seven models
ing glycol to sensible-heat exchangers instead of true of air-cooled units capable of providing 60 to 300 tons
evaporators. of refrigeration. Advanced features incorporated into
The chiller-system designs do, however, incorporate the design include variable-speed fans for air-cooled
a number of features providing advantages related to condensers, high-effectiveness condenser coils, a fully
installation cost and timing. Standard features aimed at automatic oil return, and a fully integrated program-
improving energy efficiency include: mable logic controller (PLC).
• Floating head-pressure control. The condensing unit (Figure 4) utilizes only NH 3
• Floating suction-pressure control. refrigerant. As with the chiller, refrigerant charge is
• Variable-frequency drives for condenser fans. minimized as a result of the packaged approach, along
• High-efficiency screw compressors. with a number of advanced design features, including
The chiller introduces the concept of critically charged high-effectiveness evaporator and condenser coils, an
systems, systems in which the refrigerant always is ultralow-charge, low-pressure receiver, and a highly
undergoing change (expansion, compression, heat efficient defrost methodology. The defrost methodology
transfer)—that is, there is no excess refrigerant is worth noting in that the system acts like a heat pump:
residing in the system waiting for the moment when During defrost, the evaporators act like condensers,
more refrigerant is needed in some part of the process. giving up heat to melt ice on them, and the condenser
While this is not a new concept for smaller residential acts like an evaporator, revaporizing defrost conden-
and commercial air-conditioning and refrigeration sate. (PRL with hot-gas defrost acts similarly to the “heat
systems, it represents a significant deviation from the pump” system described here, the key difference being

that, in general, PRL uses an addi- per square foot to 200 lb per square With air-cooled condensers,
tional and separate external piping foot—on a roof. energy usage typically is:
system to effect defrost, whereas The refrigerant charge of these • Condensing unit: 2.5 to 2.7 KW
the condensing system described units depends on the type of con- per TR at -10°F.
here simply reverses the flow of denser, the location of the packaged • Chiller: 1.15 to 1.25 KW per TR
refrigerant in the same pipes during system in relation to the evaporator, for a 45°F room.
defrost.) The manufacturer believes and the size of the package in rela- Not shown in Figure 4 is the
the net result is a defrost cycle that tion to the actual load requirements. manufacturer’s total inline freezing
is faster and more energy-efficient
than a traditional hot-gas defrost
cycle. The key component is a four-
port valve within the condensing
unit. This is the only valve required
for the reverse-cycle defrost, which
makes for a greatly simplified
system with far fewer valves than a
traditional hot-gas defrost system.
The condensing unit uses a unique
low-pressure-receiver (LPR) design
enabling all control valves to be
located within the condensing unit.
This eliminates the need for valve
stations at the evaporators, greatly
reducing the number of potential
leak paths, improves efficiency,
and simplifies maintenance. An
additional feature helping to mini-
mize charge is the low overfeed
rate of the evaporators. The com-
bination of the LPR and advanced
aluminum evaporators has led to a
highly efficient system with minimal
refrigerant charge, no pump, and
no valves or mechanical joints in
refrigerated rooms.
Five air-cooled models ranging in
capacity from 25 TR to 71 TR when
rated at -10˚F are being offered. The
manufacturer anticipates the release
of higher-capacity units and units
capable of blast freezing in the near
future.
Figure 4 shows the installation
of two condensing units in a typical
cold-storage facility. Units can be
ground-mounted or roof-mounted.
The idea behind roof mounting is
to be close to the evaporators and,
thus, reduce the amount of charge
in the piping system. Structural and
seismic factors, however, must be
considered when mounting a fairly
heavy package—weights of the
units range from just over 100 lb Circle 164

and chilling solution, which utilizes an evaporative,

rather than air-cooled, condenser. This package is used
for blast freezing and has been demonstrated to be
highly energy-efficient; energy usage typically is 2.7 KW
per TR for -30°F blast freezing.
In the case of packaged systems, installed cost
typically varies inversely with system size. Smaller
(under 200 TR) systems usually show an installed-
cost savings of 10 percent to 20 percent compared with
a central system (PRL). Average-size (200 to 500 TR)
systems, because of the large percentage of load going
to the blast freezers, cost about the same as a central
plant. Large (over 500 TR) systems with typical coolers
and higher-temperature freezers require a premium of
about 10 percent compared with a central system.
The design of the chiller and condensing unit is such
that most components are housed inside of a robust
package and easily accessible for maintenance. They
have a history of being relatively trouble-free. Features
include:
• Automatic oil return.
• A PLC that monitors various key parameters in
the system and issues alerts warning of developing
problems.
• Two compressors, only one of which runs at a time
under most circumstances.
• Air-cooled condensers, which eliminate the need for FIGURE 5. Self-contained refrigeration system.
water treatment.
All other maintenance listed in the manufacturer’s There are different options for condensers: air-cooled,
operating and maintenance manual is similar to that of water-cooled, central cooling tower, and advanced air-
a PRL system. cooled heat exchanger. All of the numbers in this article
Self-contained refrigeration system. Six years ago, a are reflective of water-cooled condensers with a central
self-contained refrigeration system utilizing a number cooling tower.
of proprietary technologies related to liquid feed to Figure 5 shows a “generic” system. The system
evaporators and a unique liquid-feed control algorithm operates very much like a DX system, except instead of
was conceived. The first test cell went into operation superheat at the outlet of the evaporator, vapor quality
in 2012; since then, a number of beta sites have been (the ratio of vapor mass flow to total mass flow) is
installed. In 2013, the first complete refrigeration- measured at various points in the evaporator, and liquid
system penthouse unit went into operation in place feed is adjusted accordingly.
of a flooded NH 3 system that held approximately With installation typically on the roof of buildings,
500 lb of NH 3 charge. The penthouse unit runs with structural and seismic considerations must be taken into
approximately 5 lb of NH3 charge. That charge can be account. Weight loading of each unit is estimated to be
increased by 40 percent as a safety factor, which brings 40 to 60 lb per square foot.
the total charge to still only 7 lb (approximately 0.5 lb The estimated power consumption of the system in
per ton). This represents the lowest NH3 charge of all of Figure 5 is 2.4 KW per TR.
the systems under review in this article. The installed cost of the system can vary significantly
The penthouse-style system consists of one compres- from one region of the country to another, based on
sor, one evaporator, and one liquid-feed valve system structural requirements, labor rates, weather condi-
and control system. The system can be applied to cool- tions, local codes, and more. Nevertheless, the self-
ers, docks, freezers, and blast freezers. As with all pack- contained refrigeration system takes a great deal of
aged systems, multiple stand-alone systems of varying guesswork out of installation costs in that the only major
capacity and temperature requirements will be installed on-site installation variable is the roof penetration. With
in a facility, depending on the refrigeration requirements. that in mind, installation costs for a generic system are

an estimated $7,000 per TR. in this article offer significant system. In each case, improvements
Similar to the air- and water- reductions in NH3 refrigerant in basic energy-consumption
cooled NH 3 packaged chiller and charge. The advanced DX system values can be made. Most of these
air-cooled condensing unit, the offers an impressive improvement improvements will require addi-
self-contained refrigeration system in NH3-charge inventory, but pays tional capital cost, and some may
requires less maintenance than any a penalty for its centralized NH 3 require an increase in refrigerant
type of central system. distribution system. The two CO 2/ charge.
NH 3 systems offer even greater The reader is cautioned not to rely
Summary improvements in NH 3 refrigerant too heavily on the values presented
This article reviewed five alter- charge, but introduce a challenging here, as supporting data are mini-
native industrial refrigeration sys- (though good) second refrigerant. mal, and numerous factors related
tems capable of addressing growing The air- and water-cooled NH3 pack- to facility construction (insulation,
concern over high NH3 refrigerant aged chiller, air-cooled condensing doors, vestibules, etc.) can have a
charges in cold-storage facilities. unit, and self-contained refrig- significant influence. The point of
What’s more, adoption of any of eration system offer the greatest emphasis here is that, fundamen-
these systems does not appear to reductions in NH3 refrigerant tally, the systems appear to have
negatively impact to any significant charge, but might not offer econo- very similar operating characteris-
degree such high-priority variables mies of scale in very large industrial tics from an energy perspective.
as energy, installed cost, and main- facilities.
tenance cost. • The energy consumption of each Reference
General conclusions that can be of the reviewed systems appears to 4) Pearson, S.F. (2012). Charge
drawn include: correlate fairly closely with that of minimization. Paper presented at
• All of the systems highlighted a “soft” optimized PRL refrigeration IIAR Conference, Milwaukee, WI.
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Circle 165
What Owners Need to Know About ...
Tankless
Water Heaters
Cost, space, and safety benefits of tankless solutions
By KUNAL SHAH Tankless Design

AERCO International Inc. Not all tankless water-heating solutions are alike. Fac-
Blauvelt, N.Y. tors to consider when selecting a water-heating solution
F
include heat exchanger and material of construction.
For the new generation of mechanical rooms, lower Some tankless heaters feature a durable, highly
operating costs, greater reliability, and environmental- efficient helical firetube heat exchanger that is imper-
friendliness are the name of the game. This is leading vious to thermal stress, providing greater reliability
consulting-specifying engineers, architects, and facility and extended life. All-stainless-steel construction
owners and managers to leave no stone unturned in provides similar benefits. A water-heating solution that
their search for the best possible return on investment has corrugated tubes will have a greater effective heat-
(ROI). Considering water-heating systems typically transfer surface area for thermal efficiencies as high as
are second only to HVAC systems in terms of energy 99 percent. High turndowns of up to 30:1 complement
consumption, even small gains in efficiency and cuts in the thermal efficiencies to reduce cycling and eliminate
operating expenses related to water heating can have a fuel waste, maximizing savings. Enhanced waterside
large impact on a facility’s bottom line. For this reason, flow distribution maintains constant minimum velocities
tankless water-heating systems are gaining traction. across the heat exchanger; this keeps solids in suspen-
Tankless water-heating systems offer a number of sion and greatly reduces scale dropout to maintain high-
advantages over their tanked counterparts. For efficiency performance and long life.
example, stored water in a tanked water-heating system A key specification when evaluating tankless water
must be maintained at 140°F to prevent Legionella heaters is temperature control. A swing of 10°F to 15°F
bacteria. Further, a tanked system requires a mixing is unacceptable in most applications. Fortunately, a new
valve to prevent scalding from the 140°F stored water. generation of tankless units uses advanced algorithms
These are two factors that contribute to the higher to achieve extremely tight temperature control of ±4°F.
operating costs and lower efficiency of tanked systems This allows the tankless water heater to provide a higher
compared with tankless alternatives. Additionally, level of safety.
facility space has never been at a higher premium, Today’s tankless water-heating systems also leverage
and the more compact footprint of a tankless water advanced communications technologies. These tools
heater reduces the square footage of a mechanical constantly check a system and immediately send alerts
room. if there is a fault occurrence or decline in equipment
Kunal Shah is a product solutions manager, water heaters, for AERCO International Inc., a Watts Water Technologies
company. He has a bachelor’s degree in computer engineering from Drexel University and a master-of-business-
administration degree from Binghamton University, State University of New York.

A I R A N D D I R T S E PA R AT O R S
It’s Plain.
It’s Yellow.
It Works.
Distribution
Efficiency
Considerable improvements have been made in
generating the hot and chilled water for building
comfort systems, but little attention has been given
to distributing that water efficiently. Many standard
designs and specifications still include technology that
is approaching fifty years old or leave separators out
altogether. Air and dirt in the system fluid inhibits
heat transfer, collects in the piping or equipment and
restricts flow, actually taking away from the return on
investment made in high efficiency boilers and chillers.
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A SPIRO ENTERPRISES COMPANY

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25 N. Brandon Drive www.spirotherm.com
Glendale Heights, IL 60139 info@spirotherm.com
Circle 166
What OWnerS need tO KnOW abOut ... tanKleSS Water heaterS
PHOTOS A and B. A mechanical room before (left) and after (right) tanked systems were replaced with tankless systems.
performance. This reduces energy ROI by lowering costs, maximizing a tank-type water-heating system.
waste, increases productivity and space, providing a safe environ- Additionally, ancillary equipment,
efficiency, and prevents lost revenue ment, and lasting much longer. such as storage tanks, circulators,
caused by unexpected downtime. Economic advantages. Tankless and mixing valves, is eliminated.
water heaters lower operating costs This lowers installation and mainte-
Benefits with high efficiency (typically, 96 to nance costs considerably.
Tankless water heaters help 99 percent) and high turndown. With Space savings. A tankless-water-
engineers, architects, and facility no hot-water storage, heat-radiation heater solution requires one-quarter
owners achieve the best possible loss is less than one-quarter that of the square footage of a comparable
tank-type system, resulting in more
SIZE REALLY
room that can be used to generate
income instead of storing water.
Photos A and B show a mechanical
DOES MATTER.
room before and after tanked sys-
tems were replaced with tankless
systems.
Safety. Spikes in hot-water tem-
perature can cause burns, espe-
cially among children and seniors. A
tankless water heater can maintain
water temperature at a safe level of
less than 120°F to reduce the risk
of scalding, while eliminating the
ne ed fo r c os tl y sy ste m m i xi ng
SAM-JR valves. Because water volume is
minimal and circulation is continu-
ous, a tankless design virtually elimi-
Get boiler tubes cleaner, faster!
nates the risk of Legionella bacteria
• Small size, big punch. Lightweight and growth as well.
powerful, SAM-JR pounds soot from tubes
Life cycle. With a life of 20-plus
up to 21/2″ I.D.
• Dial-In Technology. Set tube length once years, tankless water heaters last
and punch away. two to three times longer than
• Ergonomic Design. Small size saves tired SootVac ® -JR tank-type heaters, which typically
backs and shoulders. need to be replaced every eight to
CALL 888 364-3445 10 years. Glass-lined storage tanks

www.goodway.com/tubecleaning have even shorter service lives of
three to five years and are prone to
rust and failure when potable-water
Circle 167 chemistry is less than ideal. Tank-

What OWnerS need tO KnOW abOut ... tanKleSS Water heaterS
less water heaters with advanced operating costs and reduce the risk found in dormitories, which will
condensing and modulating tech- of guests being scalded. When this lower operating costs.
nology, along with a stainless-steel level of performance is paired with Multifamily. Nowhere is mechan-
helical firetube heat exchanger, a proactive remote monitoring tool ical-room space more critical than
provide a highly reliable solution. that prevents unexpected downtime, in a multifamily building. Use of a
Tankless water heaters can be guests always will have hot water. tankless water heater frees up space
designed with onboard multiunit Health care. Hospitals, medical that can be used to generate revenue
sequencing logic for efficient daisy- centers, and other health-care facili- (e.g., an additional apartment and/
chaining to meet load requirements. ties must have continuous hot-water or parking spot). This is particularly
This minimizes cycles per unit to service. When selecting a tankless important in a city or metropolitan
extend the life of the heaters, while water heater, facility owners and area, where space is at a premium
significantly reducing service and managers do not have to be con- and real estate is expensive.
maintenance costs and maximizing cerned with Legionnaires’ disease or
system efficiency and turndown. patients being scalded. Additionally, Conclusion
they avoid the cost associated with From providing safe, non-
Versatility purchasing mixing valves, which scalding hot water instantaneously
Virtually any facility in need of are necessary for a tanked system to without the need for a storage
hot water can realize the benefits of provide similar assurances. tank to maximizing space with a
tankless water heaters. Education. For campus environ- reliable system built to last two
Hospitality. A tankless design ments, engineers should select the to three times longer than tanked
that allows outlet temperatures to tankless design with the highest systems, tankless water heaters
be set to 120°F without the risk of possible turndown. This will allow are the most advanced hot-water
Legionella bacteria, as well as tight the water heater to meet the low solution available and provide the
temperature control, will lower flow and peak demands commonly greatest ROI.
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Circle 168

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Circle 169 uponorengineering.com/commercialpiping
Proper Procedure
for a Boiler-Room
Assessment
Improving efficiency, sustainability, reliability, safety
E
fficiency, sustainability, reliability, safety—these are stack loss, steam and feedwater flow, moisture in stack gas,
the keys to the optimal performance of a facility, and and fuel-meter clocking for actual input, into account.
they are the focus of a properly conducted boiler-room The goal is safe, efficient combustion and optimal heat
assessment. This article discusses what goes into a properly transfer. To accomplish this, a burner typically will be set
conducted boiler-room assessment. at about 3 percent oxygen or 15 percent excess air, which
Because it requires a specific methodology and expertise, is where it should operate most of the time. For every
a boiler-room assessment—for most facilities—is best 2-percent increase in oxygen over the benchmark, there will
performed by an outside specialist. be a 1-percent loss in efficiency.
By STEVE CONNOR and RANDY SMITH, PE, CEM The assessor then will observe
Cleaver-Brooks
Efficiency Thomasville, Ga.
how well the boiler (heat exchanger)
The first step in conducting a boiler- absorbs heat from the burner. If the
room assessment is to determine burner is operating and combusting
facility steam cost. When figuring steam cost, many consider properly, flue-gas temperature should be approximately 50°F
only fuel cost, boiler efficiency, and cold-water makeup. This to 100°F above saturated temperature. In other words, if the
calculation is “unloaded” because it does not include other boiler is operating at 100 lb with a saturation temperature
costs associated with the production of steam. A “loaded,” or of approximately 340°F, the stack temperature should be
true, cost of steam production includes all of the above plus between 390°F at low fire and 440°F at high fire. For every 40°F
labor and maintenance, chemicals, and waste charges. increase over this base point, there will be a 1-percent loss in
Various terms are applied to efficiency. For instance, efficiency.
combustion efficiency sometimes is used to refer to boiler The assessor also will look for possible climatic variables,
efficiency, but it really is the ability of a burner to combust including relative humidity in the boiler room, barometric-
fuel with the least amount of excess air without exceeding pressure fluctuations, and ambient air temperature. If
or compromising acceptable levels of carbon monoxide ambient temperature changes frequently and the boiler
and safety. Thermal efficiency is overall boiler efficiency modulates a lot, the system would benefit from an oxygen-
before subtracting radiation and convection (R&C) losses. trim system, which optimizes combustion controls, keeping
Fuel-to-steam efficiency is the true reflection of how a boiler the fuel/air ratio consistent.
is performing, as it is net of R&C losses. This is the correct While taking note of climatic conditions, the assessor will
indicator of useful energy going out to a system. be paying close attention to the burner’s combustion-control
A boiler-room assessor will determine fuel-to-steam system, particularly the modulation frequency. The assessor
efficiency by evaluating the physical condition and features will look at the turndown capability of the burner, how the
of a boiler’s burner and determine actual efficiency using the burner is tracking the load, and how frequently the burner is
procedure outlined in ASME PTC 4-2008, Fired Steam Gen- cycling.
erators. The procedure takes a number of variables, including In addition to the boiler, areas of the boiler room the
Steve Connor is an expert in steam- and hot-water generation with more than 50 years of experience. He recently retired from Cleaver-Brooks as
director of technical and marketing services. Randy Smith, PE, CEM, is a sales engineer with Cleaver-Brooks’ Boiler Plant Optimization group, which
focuses on improving facilities’ steam generation, distribution, consumption, and condensate return. He has more than 25 years of industrial and
boiler-plant experience.
Boiler Systems Engineering SEPTEMBER 2015 BSE1

P R O P E R P R O C E D U R E F O R A B O I L E R - R O O M A S S E S S M E N T
assessor will evaluate include the with the addition of an economizer. maintain proper conductivity. If effluent
exhaust-stack/breeching arrangement For every 40°F drop in stack tempera- is going down the drain, a blowdown
and support accessories. Often, a great ture, there will be a 1-percent gain in heat-recovery system, which puts valu-
deal of energy will be lost through the efficiency. able energy into a boiler’s feedwater
stack. If a boiler is more than 150 hp and Next, the assessor will observe how stream, likely will be recommended.
is operating at over 100 lb of pressure, the boiler is set up to control totally Other support accessories, along
some of this energy can be recouped dissolved solids in boiler water to with the amount of condensate com-
ing back from the system, also will be
checked. If little is returning and a lot
of raw makeup is entering, a carbon
filter may be required, if one is not
already in place.
The assessor will perform chemical-
treatment analysis to determine
whether there is a high degree of
carbonate/bicarbonate alkalinity. If
there is, the addition of a dealkalizer
may reduce blowdown and further
protect the system. The assessor then
will examine the boiler feed system
(vented or pressurized), as well as the
chemical feed system.
While its primary emphasis will be
on boiler-room equipment, a com-
prehensive assessment will take into
account where and how effectively
steam is being used. Specifically, the
assessor will check piping through-
out the plant to see if it is insulated
properly. If it is not, valuable energy is
being wasted to the process, and the
chance of damaging water hammer is
heightened.
At the same time, the assessor will
look for steam traps. Whether catego-
rized as thermodynamic, mechanical,
or thermostatic, all traps serve the
same purposes: trap steam, purge air,
and evacuate condensate.
Air has a negative effect on pro-
cesses. It can significantly reduce
steam temperature and, thus, heat
transfer. When air and other gases
enter a steam system, they consume
volume steam otherwise would
occupy. The temperature of an air-
steam mixture is below that of pure
steam.
In terms of air elimination, traps
can do only so much. Air vents need
to be placed in strategic locations
to eliminate air or partial-pressure
Circle 170 conditions. For example, if a steam
BSE2 SEPTEMBER 2015 Boiler Systems Engineering
Efficiency & Versatility.
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pressure loss of the vessel, there is no requirement for a
dedicated boiler pump. The robust design of the SB Series
high mass boiler is high efficiency condensing boiler technology
at its best – and it’s built to last with a Titanium infused stainless
steel heat exchanger. The full-swing door provides easy access
to the combustion chamber & flue passages resulting in lower
maintenance costs. The SB Series - who knew efficiency
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and domestic hot water.
Circle 171
P R O P E R P R O C E D U R E F O R A B O I L E R - R O O M A S S E S S M E N T
line is heating a process load at 86 psig, the temperature combustion efficiency, there is an array of high-efficiency,
of that steam will be 328°F. If air is mixed with the steam, low-emitting burners to dramatically reduce nitrogen-
which amounts to 10 percent of the volume, the temperature oxide and carbon-monoxide emissions. The assessor will
will drop to 321°F, or the equivalent of 76 psig, even though evaluate current systems and recommend additional ways
the steam gauge is registering 86 psig. This extends process to conserve natural resources and reduce emissions.
time and wastes energy. If a system has another source of fuel, such as landfill gas
An assessor will note how traps are piped, where traps or digester gas, that is being wasted (flared off) or hauled
are located, and if the drip pocket is sized correctly with the away, there are technologies that may be used to burn it.
proper drain valve installed at its bottom.
The assessor will note whether condensate is returning to Reliability
the boiler room by gravity, shear motive force, or mechanical The assessor will thoroughly check the burner, its
means. Equally important, the assessor will want to know combustion-control system, and its burner-management
if condensate is overloading the return system and, thus, system (BMS). It is important a BMS provide all lockout
is in need of venting; if it is, a surge tank in the boiler room information in a clear and readily understandable way and
working in conjunction with the existing feed tank likely have the capacity to log and store fault history.
will be recommended. Today’s programmable-logic-controller-based systems
integrate not only burners, but all accessory equipment.
Sustainability Integrated systems are important for reliable service and to
Facility owners and managers are seeking ways to keep operators informed and able to anticipate and quickly
conserve natural gas, oil, air, and water. Fresh water not only remedy unexpected outages.
is an ongoing operational cost, it is becoming scarce, which is An important contributor to reliable boiler operation
one of the reasons returning condensate is so important. is an ongoing maintenance program that includes regular
In terms of reducing emissions while improving combustion analysis. Keep all service records detailing
when tune-ups, including efficiency checks, were performed.
The assessor will want to review the records. One of the
things he or she will look for is elevated stack temperature,
Never A Compromise which can indicate fireside or waterside fouling. Along
For Quality or Safety with energy loss, elevated stack temperature can seriously
damage a boiler.
In addition to service records, the assessor will ask for
205 TC SERIES critical and dynamic records. Critical records include the
CONDENSING manufacturer’s data report, equipment documentation,
HOT WATER BOILERS a list of suppliers with contact information, a spare-parts
list, operating manuals, wiring diagrams, and standard
operating procedures. Dynamic records include startup
and tuning reports, repair reports, inspection reports,
chemical-analysis reports, and the boiler-room log.
Safety
Properly functioning low-water cutoffs and properly
piped safety valves are key safety check points. The assessor
will look at steam-line-drip-pocket sizing and location,
along with steam-trap location and functionality. Improper
sizing, location, and function of steam-line drip pockets
and steam traps can cause dangerous water hammer.
• BIO GAS • HEAVY DUTY FIRE
The main and auxiliary low-water cutoffs and the piping
• NATURAL GAS, TUBE TYPE DESIGN for the boiler’s safety relief valve(s) also will be checked.
PROPANE, #2 OIL • ALL STAINLESS STEEL
• 399,000-5,443,000 CONDENSING FLUE Once the assessment is complete, the assessor will
BTU/INPUT PASSAGES
• UP TO 99.7% • NO CAST review his or her findings with facility management and
EFFICIENCIES REFRACTORY
Low NOx Models
MATERIAL SCAQMD Certified to 1146.2 prepare a report that includes recommendations for the
facility going forward. The report likely also will include
PARKER BOILER CO Ph. (323)727-9800 www.parkerboiler.com
5930 Bandini Blvd, Los Angeles, CA 90040 Fax (323) 722-2848 sales@parkerboiler.com markups of the plant’s process and instrumentation drawings
detailing recommended changes.
Circle 172
Circle 173
Hot-Water-
and Steam-Boiler
Water Treatment
Avoiding tube and system failure, performance loss
I
n boiler systems, nearly all problems related to premature fire-tube-type boilers in the 10-to-1,000-hp range. Fire-tube
water- and fire-tube failure, unexpected performance boilers are more robust and more tolerant of poor water qual-
loss, and system failure can be traced to water chemistry ity, but require more physical space, than water-tube boilers.
and treatment. Taking the steps to develop and maintain an Regardless of boiler type, water quality is a critical aspect
efficient and reliable water-treatment program will ensure a of implementing and operating an efficient steam plant.
successful boiler system. Key components of steam-boiler water treatment include
With a boiler system, the importance of water treatment makeup-water treatment, oxygen removal, and feedwater
is determined largely by the type and treatment.
application of the boiler. There are many By COREY LEHMAN, PE
Southland Industries
types of boiler applications, the primary Garden Grove, Calif.
Mathematical Relationships
ones being hot water and steam. In most plants, steam losses can be signifi-
cant, varying from 30 percent to 80 percent
Hot-Water Applications of total boiler output. These losses can be attributed primarily
In hot-water applications, boilers typically operate within to leaks and processes that leave condensate in a contami-
a stable closed-loop system in which the water chemistry is nated or unrecoverable state.
fairly constant. This means water is treated and stabilized for Fresh makeup water is required to account for condensate
use during the initial fill of the system. Periodic checks and losses in a system. Scale-forming minerals are removed as the
minor chemistry modifications are needed to keep the loop first line of defense in controlling water chemistry and steam
under control, provided there are no major leaks introducing quality. This can be done through precipitation softening, ion
large amounts of raw makeup water. exchange, or reverse osmosis. Makeup-water-supply quality,
In hot-water systems, water quality tends to be less of an economics, and the end use of the steam often dictate which
issue and more predictable, which leads to tighter tolerances. approach is most appropriate. For most commercial and light-
In the light- and small-commercial market, the most common industrial applications, an ion-exchange softening process is
types of boilers include copper fin, cast iron, high mass, and, utilized to minimize costs.
whether condensing or non-condensing, water tube. Fire- Condensate return water is combined with treated makeup
tube boilers are available in this market, but usually require water and deaerator steam to produce boiler feedwater. This
more installation space than comparable-output water-tube feedwater is introduced to the boiler, and mostly pure steam
boilers. In water-tube boilers, flue gases surrounding tubes is boiled off. During the boiling process, all of the solids and
heat water inside of the tubes. In fire-tube boilers, flue gases impurities left behind in the boiler become concentrated. This
are inside of tubes, and water is in the shell around the tubes. requires blowdown or a deliberate bleeding off of the boiler
water. With the blowdown having to be made up as well, the
Steam Applications total makeup can be expressed as follows:
In steam applications, water quality is an important part of
boiler selection. Steam boilers tend to be steel water-tube- or TM = SL + CL + BL
Corey Lehman, PE, is an associate principal and HVAC- and plumbing-system designer with Southland Industries, a national mechanical, electrical,
and plumbing building-systems firm. He holds bachelor’s and master’s degrees in architectural engineering from The Pennsylvania State University.
He can be reached at clehman@southlandind.com.

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Circle 174
H O T - W A T E R - A N D S T E A M - B O I L E R W A T E R T R E A T M E N T
where: per hour (kilograms per hour) TDS C = TDS in recovered steam
TM = total makeup condensate, milligrams per liter
SL = steam losses Often, mass-flow rates are not TDSMU = TDS in makeup, milligrams
CL = condensate losses known, in which case the percentages per liter
BL = boiler water losses can be calculated based on a ratio
concentration of a dissolved solid or The quantity of dissolved solids
Makeup and blowdown can be total dissolved solids (TDS) in the in boiler water compared with that
represented in terms of a percentage of different streams: in feedwater can be described in a
feedwater, when the flow rates of these concentration ratio or cycles of concen-
TDSFW
streams are known. Their relationships %BD = 100% × ____ tration (COC). In the simplest terms, it
TDSBD
are expressed as follows: is the reciprocal of the percentage
where: blowdown:
BD
%BD = 100% × ___ TDSFW = TDS in feedwater, milligrams
FW 100
per liter COC = ____
%BD
TDSBD = TDS in blowdown, milligrams
MU
%MU = 100% × ___ per liter Often, when makeup water is
FW
demineralized, COC cannot be cal-
where: The percentage makeup can be culated using a conductivity probe.
BD = blowdown mass flow, pounds calculated as follows: Fluorescing tracer chemicals can be
per hour (kilograms per hour) utilized to determine the ratio of
TDSFW − TDSC
MU = makeup mass flow, pounds per %MU = 100% × ___________ concentration of boiler water to feed-
TDSMU − TDSC
hour (kilograms per hour) water. Another approach is to measure
FW = feedwater mass flow, pounds where: the steam being produced and the
Circle 175 Circle 176

blowdown flow rate to calculate COC: ing oxygen and dissolved gases is • Methylethylketoxime (C4H8NOH).
the deaerator. There are several • Hytroquinone [C6H4(OH)2].
S + BD
COC = ______ methods of deaeration; selection In most commercial and light-
BD
depends on the size of the system, industrial applications, sodium sulfite
where: the type of gases, the concentration is used to control oxygen beyond the
S = steam mass flow, or boiler output, to remove, and economics. The most capabilities of deaerators. However,
pounds per hour (kilograms per hour) common types are spray, tray, and sulfite adds solids and contributes to
atomizing. For most small to medium- the need for increased blowdown flows.
Removing Oxygen and sized commercial installations, Other scavengers can double as metal
Gases spray type is the most compact and passivators, protecting equipment
Another important function of economical. and piping, in addition to reducing
boiler-feedwater treatment concerns Effective deaerators reduce oxygen oxygen levels. Many other compounds,
the removal of oxygen and dissolved levels in feedwater to about 0.007 to however, break down into carcinogenic
gases, such as carbon dioxide and 0.04 mg per liter (7 to 40 μg per liter). and acidic components.
ammonia. The presence of these Often, additional oxygen removal is
gases can result in corrosion that accomplished with a chemical scaven- Scale Control
ultimately causes tubes to fail and ger. Commercial oxygen scavengers Mineral scale is comprised largely of
piping to rupture and leak. Carbon on the market include: precipitates of calcium and magnesium
dioxide primarily affects condensate • Sodium sulfite (Na2SO3). salts. Although ion-exchange water
systems, as it turns to carbonic acid, • Hydrazine (N2H4). softening largely removes scale-
which can aggressively deteriorate • Carbohydrazide [(NH2NH)2CO]. forming agents, feedwater should be
components. • Erythorbate (RC6H6O6). monitored regularly to ensure none is
The primary mechanism for remov- • Diethylhydroxylamine [(C2H5)2NOH]. being introduced from other sources.
Algae Insects
Water filter optimizes
Airborne
heat transfer efficiency
Leaves Particles
Pollen
PROBLEM:
Airborne dust and debris, microbiological
Cooling growth, pollen and other materials collect
Tower
Heat in cooling towers. Combined with calcium
Exchanger
carbonate, magnesium silicate, rust, iron
chips, scale and other corrosion by-products,
Rust they reduce heat transfer efficiency.
Water
Filter
SOLUTION:
Line pressure powered Orival water filters
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Circle 177
Boiler Systems Engineering SEPTEMBER 2015 BSE9
Silica scale also can be a problem,

although it rarely is found in systems
below 600 psig. Silica deposits can
form when boilers operate at excessive
COC or pretreatment softeners are
not designed to remove silica. For
most applications in the western
United States, where most water
comes from the melting of mountain
snow pack, mineral scale is the larger
culprit.
Whereas scale associated with
water hardness used to be the
main cause of boiler failures, the
push to return as much condensate
as possible has led to increased iron
deposits in boilers. Iron deposits on
heat-transfer surfaces now are the TABLE 1. Common issues and system areas affected.
predominant mode of failure. As
deposits accumulate, they act as mild steel at high temperatures under feedwater system, and include neces-
insulators, impairing heat transfer. alkaline-reducing conditions, or high sary components in the design.
This ultimately causes metal to over- pH, will form a protective magnetite- • Consider that operators may
heat and fail. The porous nature of oxide (FE 3 O 4 ) layer on the surface, not know how to maintain effective
the deposits exacerbates the situation protecting the base material. water-treatment programs. Have the
by trapping corrosive chemistries, Special care should be exercised water-treatment service provider
such as caustic acid phosphates, in monitoring and protecting oxides. conduct detailed training. Consider
sulfates, and chlorides. Unfortunately, As boilers and systems are taken recording the training for future
even after significant research initia- offline and restarted, the expansion reference.
tives, the deposition mechanism of and contraction of metals can cause • Employ thorough monitoring
iron deposits on boiler surfaces is not oxides to crack and flake off, exposing procedures, frequently checking water
well-understood. the base metal to continued corrosion. chemistry at different control points
Most iron originates from raw-source Additionally, caustics or acids can within the system, and document
makeup water or the corrosion of mild- interact with oxides and cause them results. Elevated temperatures can
steel components within a steam and to break down. For this reason, the cause chemistries to go out of spec
condensate system. Corrosion of mild recommended pH is in the alkaline quite rapidly. Knowing the normal
steel is influenced by factors such as rage of 9 to 12. tolerance ranges and monitoring
pH, temperature, heat flux, dissolved Table 1 summarizes common prob- frequently (two or three times a day)
oxygen, carbon dioxide, flow, ionic lems and affected areas. can prevent scale and iron deposition
strength, suspended solids, and boiler- from escalating beyond recoverable
treatment chemicals. Fortunately, Key Takeaways limits.
Following is advice for developing • Keep it simple. The simpler the
a water-treatment program: design and program, the greater
• Be willing to invest in a high-quality the likelihood operators will stick
program from a reputable service to it.
provider. Good treatment programs
can save costs attributed to shutdowns Reference
for tube or equipment replacement. Flynn, D. (2009). The Nalco water
• Take a proactive approach. Actively handbook (3rd ed.). McGraw-Hill.
engage a reputable water-treatment
service provider to assist in the Did you find this article useful?
development of a program tailored to Send comments and suggestions to
your system. Also, test the makeup- Executive Editor Scott Arnold at scott
Iron deposits inside tube. water source and any condensate or .arnold@penton.com.
How a high school lowered
fuel expenses by letting us
do the homework.
Completely integrated boiler solutions can generate results for you, too.
When a regional high school installed six ClearFire®-C fully condensing boilers in their
new building, they cut fuel consumption and became one of the first certified
Green Schools in Massachusetts. Read about this case study and others at
cleaverbrooks.com/highschool or call 1-800-250-5883 to locate your local rep.
©2015 Cleaver-Brooks, Inc.

Circle 178
N E W S & A N A L Y S I S
Industrial Boiler Operators There is another important twist

with NOx: In some places, NOx has
been identified as the more important
Bracing for Ozone Decision ozone precursor. Air-quality models
in North Carolina, for example, cite
Announcement likely this month natural sources (trees, forests) as the
source of VOCs. No one is going to
By TOM EWING must be kept under 20 tons per day. clear-cut the Smoky Mountains. In this
Special to Boiler Systems Engineering
That total helps in setting the emission respect, again, a lower ozone standard
M
ost likely this month, the allowance for each source category. If would put new pressures on NOx and
U.S. Environmental Protec- regulators decide the industry sector new pressures on all sources.
tion Agency (EPA) will decide (stationary sources) has to stay under At individual facilities, boiler opera-
whether to lower the permissible level 7 tons per day, individual operating tors face difficult questions: If required
of ground-level ozone, a move that permits will reflect that regional to scale back NOx, what are the options?
would affect business operations and sum. Are they cost-effective? Do competi-
economic development throughout Among business advocates, there tors face the same requirements? There
the United States, with some cities are two basic concerns with the are no easy, standardized answers.
and regions—even within the same proposed reduction. First, how will With ozone, regulatory uncertainty is
state—impacted more than others. emissions allowances for each source part of the game. It can take years for
By law, the EPA has to review the category—mobile vs. stationary vs. the dust to settle regarding who has to
adequacy of its air-quality standard area—shift? Second, critics claim do what and to what extent.
every five years to ensure it is set at the EPA is too vague regarding the On the technical side, options for NOx
a level deemed protective of the controls that could deliver the required control are part of regular engineering
public health. The current standard, reductions. The EPA contends a lower reviews. Control options include switch-
set in 2008, is 75 parts per billion (ppb). standard largely will result from cur- ing fuels, flue-gas recirculation, and
In December 2014, after the most rent control policies, some of which catalytic/non-catalytic reduction. More
recent review, the EPA announced are new. Critics disagree, arguing the extremely, NOx control could mean
the possibility of lowering the standard nation will not just slide into compli- scrapping a boiler prematurely or even
to a level between 65 ppb and 70 ppb. ance on the cheap, so to speak, and that shutting it down.
Ozone is a colorless, odorless gas a 65-to-70-ppb standard will require Currently, there is a critical parallel
formed largely from two “precursor significant new controls to reduce NOx issue: the boiler Maximum Achievable
pollutants”—nitrogen oxides (NOx) and VOCs. The National Association of Control Technology (MACT) rules,
and volatile organic compounds Manufacturers, which has led the established to control hazardous air
(VOCs)—primarily on hot, sunny days. business critique of the EPA’s proposal, pollutants. The MACT compliance
At certain exposures, it is linked to calls the possible ozone revision the deadline is Jan. 31, 2016.
lung and breathing problems. costliest regulatory program ever. The Council of Industrial Boiler
To control ozone, regulators focus A lower ozone standard presents Owners (CIBO) has prepared a timeline
on NOx and VOC emissions from: critical concerns for industrial non- for boiler MACT compliance. CIBO’s
• Mobile sources—mostly cars and electric-generating-unit (non-EGU) schedule suggests construction and
trucks, but also marine, rail, and off-road boilers, particularly regarding NOx. installation should be taking place
engines. Historically, EGU boilers have been the now for the January deadline to be
• Stationary sources—industries and primary NOx targets. With a change met. A question keeping facility owners
electric utilities. from 75 ppb to perhaps 65 ppb—which and operators up at night is this:
• “Area sources”—the “mom and would be significant—regulatory scope What if your boiler MACT project is
pop” scale of business-related pollution. would expand, and NOx emissions spot-on, but then NOx is judged too
Within a metropolitan area, or “air from non-EGU boilers, especially large high because regulators are looking
shed,” environmental regulators seek boilers, would get new attention. for ways to implement a lower ozone
to develop regional NOx- and VOC- Utility-sector NOx control is reaching standard?
emission “budgets.” For industry, a NOx its limits. And with Congress not par- While the ozone standard is
or VOC budget is implemented within ticularly supportive of the EPA’s recent national, pollution-control programs
a state’s system of operating permits. carbon-dioxide/climate-control pro- vary throughout the country and
Regulators may determine, for example, posals, the profile of non-EGU boilers even within states. That is because air
that total NOx emissions in an air shed would be raised. quality is worse in some metropolitan
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Circle 179
N E W S & A N A L Y S I S
areas than others. Think of a facility compliance. State governors would 70 ppb, all of these regions likely will
in Los Angeles and one in Columbus, be asked to determine the degree of be judged more harshly, with busi-
Ohio. Other factors being more or less “non-compliance” (e.g., “marginally,” nesses facing new and more stringent
equal, the facilities will demand very “moderately”). The EPA then would pollution-control policies.
different approaches for additional review the governors’ proposals Business managers are wise to pay
NOx control. and make a final decision regarding close attention to the evaluation and
New NOx issues would create level of non-compliance, with decisions ranking of metropolitan areas. By
competitive issues as well. If your due in October 2017. doing so, they will better understand
facility is in Los Angeles and your Importantly, these are not casual the ramifications for their operating
competitor’s is in Columbus, the rankings. Control programs in areas, if a new standard is enacted.
emission-control impacts from a “marginal” areas are less exacting Additionally, they will be able to
revised ozone standard could be than those in “moderate” ones. There participate in proposals about new
quite disparate—same national are yet higher rankings for “serious,” controls and influence final decisions
standard, much different programs. “severe,” and “extreme” areas of the via trade organizations and elected
Would your competitor have the country. Under the current standard officials. Now is the time for them to
advantage? of 75 ppb, LA-South Coast is considered sharpen their advocacy skills.
If a new standard were to be “extreme,” while Ventura County, Stay tuned for updates.
announced, states would be required Calif., is considered “serious.” Dallas-
to determine whether ozone readings Fort Worth is a “moderate” area. Thirty- Tom Ewing is a Cincinnati-based
in urban areas met the new standard, six metro areas, from New York to freelance writer focusing on business
whether regions were “in compliance.” Cleveland to Denver to San Francisco, and economic-development issues
Depending on the EPA’s final numbers, are considered “marginal.” With a new linked to air quality, particularly ozone,
hundreds of counties could be out of lower standard between 65 ppb and and U.S. EPA regulatory oversight.
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Circle 180

Circle 181
P R O D U C T S P O T L I G H T
CHANGING TO
HIGH EFFICIENCY? Condensing gas boilers
UTILIZE YOUR SlimFit high-efficiency condensing
EXISTING VENT! gas boilers have been enhanced to
include improved boiler-to-boiler
FasNSeal 80/90 is a unique, communication, Modbus and BACnet
patent pending system that for linking with building automation
exhausts 90+ condensing systems, an express setup wizard, 10
appliances with Type B preset typical heating systems, and an
atmospheric units within updated controls interface for simpler
navigation, at-a-glance boiler status,
the same vent.
diagnostics, and troubleshooting.
Using your preexisting common vent,
our cap improves the operation of
both the remaining atmospheric alarm condition is detected, PV-A
appliance, and the new condensing will text up to three phone numbers.
unit, while not disturbing fnished If the alarm is cleared, an additional
space during installation. text will be sent to an off-site owner or
operator. PV-A can be purchased as a
Finally a solution when you need
standalone device and installed in the
to deal with narrow lot lines,
The boilers’ narrow housing offers im- field by others or provided mounted
clearance to window and door
proved maneuverability for confined on a new boiler.
openings or when side wall venting
spaces and weight-restricted areas. —Parker Boiler Co.
just isn’t practical.
Additionally, the units come com- www.parkerboiler.com
pletely factory-assembled, allowing
for on-site plug-and-play installation, Gas condensing boiler
lowering installation costs and ensur- A compact gas condensing boiler in a
ing timely project completion. floor-standing de-
—Weil-McLain sign, CU3A is easy
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new-construction
Water heaters/boilers and retrofit appli-
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heaters/boilers 1,592 MBH is pos-
are designed with sible. No primary/
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Five models rang- tio for efficiency of 95 percent AFUE,
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Circle 182
boilers and other devices. When an http://uncompromise.us
BSE16 SEPTEMBER
MONTH YEAR2015
Boiler
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Circle 62
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Why Should You

Filter Your Water?
Scale formation reduces the heat transfer rate and

increases the water pressure drop through the heat
exchanger and pipes. In fact, one study has shown
that .002" fouling will increase pumping needs by 20%.
The Best Engineered Water Filtering

Solution Always Costs Less
2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A
( 8 0 0 ) 3 3 6 - 194 2 ( 310 ) 8 3 9 - 2 8 2 8 F a x : ( 310 ) 8 3 9 - 6 87 8
w w w. t e k l e e n . c o m i n f o @ t e k l e e n . c o m
Circle 61
Circle 63
SEPTEMBER 2015 HPAC ENGINEERING 47

AD INDeX
Installs
in no
CirCle No. Page No. CirCle No. Page No.
185 AAON bC 174 Hurst boiler bSe7

time 156 AerCO International Inc. 11 173 John Zink Co. bSe5
180 Aeroflex USA Inc. bSe14 150 Loren Cook Co. IFC
F L AT 155 AHr expo 9 182 m&G DuraVent bSe16
154 Air Solution Co. 7 183 metraflex 48
168 Armacell LLC 29 158 mitsubishi electric 13
Metraloop® 171 bosch

thermotechnology bSe3
162 multi-Wing America Inc. 19
seismic joints
160 Navien 15
157 buckaroos Inc. 12
177 Orival Inc. bSe9
Pre-assembled. 159 Cambridge engineering Inc. 14
172 parker boiler Co. bSe4
178 Cleaver-brooks bSe11
Pre-tested. 152 Danfoss 2
163 Quietside/Samsung 21
176 Shortridge Instruments bSe8

Two connections. 151 ebm-papst 1
166 Spirotherm Inc. 27
170 eCOm America bSe2
Done. 184 titus IbC
165 evapco Inc. 25
153 trane Commercial 5
175 Flaretite Inc. bSe8
169 Uponor 30
167 Goodway technologies 28
164 Vaisala 23
161 Greenheck Fan Corp. 17
179 Ward manufacturing bSe13
181 Hilmor bSe15
For free information about the products and services featured in this issue, circle the
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Slee
wel p
l
Alex ,
.
Some environments are more critical than others.

When proper air management can mean the diference
between a good night’s sleep and contamination,
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HPAC - Boiler RM Assesment

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SEPTEMBER 2015 | www.hpac.

Minimizing Ammonia Charge

•Proper Procedure for a Boiler-Room Assessment

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