AUGUST 2014 | www.hpac.

com

A Penton Publication

USPS 100 APPROVED POLY

Design Solutions: Planning for New

Biomedical Facility Puts Energy
Efficiency Under the Microscope
What Owners Need to Know
About Duct-Free HVAC
Evaluating Power-Demand
Reduction With
VFD-Controlled Systems

Improving the Efciency of

Small to
Mid-sized
Buildings

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'5,9(1
72372%27720

Yaskawa drives offer the quality performance you need for your assets from the air handlers and cooling
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Our Z1000, for example, is a variable speed drive that is designed for building automation applications such
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2014 Yaskawa America Inc.

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Just for once, were not

thinking outside the box.

The line of radial plenum fans with GreenTech EC motor technology has been
expanded again. And with the new product line comes a new name: RadiPac.
The RadiPac is equipped with motor, intelligent & aerodynamic impeller design,
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save space; thanks to plug and play it also reduces complexity. One more
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More information about air conditioning and ventilation systems with EC can
be found at http://radipac.ebmpapst.us

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The engineers choice

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Choose Honeywell Commercial HVAC Components.

When you specify Honeywell field devices, youre choosing more than exceptional
products. Youre choosing the industrys most comprehensive line of valves, actuators,
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Download the Fast Track tool and simplify everything from estimating through delivery
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2013 Honeywell International Inc. All rights reserved.

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INSIDE HPAC ENGINEERING

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PUBLISHING OFFICES:

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FEATURES:
SCHOOLS AND UNIVERSITIES/MANUFACTURING AND INDUSTRIAL/HOSPITALS AND HEALTH CARE/
COMMERCIAL OFFICE BUILDINGS/GOVERNMENT BUILDINGS

14

DAN ASHENDEN
Group Publisher,
Mechanical Systems/Construction
.*$)"&-
8&*Editorial Director
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Executive Editor

COMMERCIAL OFFICE BUILDINGS

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Production Coordinator
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Audience Development Manager
ANGIE GATES
Group Digital Director

NORTH CENTRAL/NEW ENGLAND/SOUTHEAST

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MID-ATLANTIC
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Chief Executive Officer

ISSN 1527-4055
HPAC Heating/Piping/Air Conditioning Engineering
is published monthly by Penton Media, Inc., 9800 Metcalf
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What Owners Need to Know About Duct-Free HVAC

The fastest-growing segment of the U.S. HVAC market, variablerefrigerant-flow (VRF) zoning is a flexible, cost-effective, and
environmentally friendly HVAC option for commercial buildings with
multiple floors and areas. This article discusses seven primary
characteristics of VRF zoning technology.
By Pamela Androff, PE, LEED AP

$0//*&
$0/,-*/
Art Director

SALES OFFICES:
CALIFORNIA/TEXAS
3"/%:
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908 Electra, Austin, TX 78734
512-263-7280 t Fax: 913-514-6628
e-mail: randle.jeter@penton.com

Improving the Efficiency of Small to Mid-Sized Buildings

The latest technological advances have made control and systemintegration capabilities available and affordable for small and mid-sized
buildings, while providing functionality similar to that of large building
automation systems. By knowing how to take advantage of these systems,
a variety of savings can be realized throughout a buildings life.
By Chad Senger

-*/%"
3&*/)"3%
Vice President & Market Leader,
Electrical Systems, Mechanical Systems,
Energy & Construction

SCHOOLS AND UNIVERSITIES/MANUFACTURING AND INDUSTRIAL/HOSPITALS AND HEALTH CARE/

COMMERCIAL OFFICE BUILDINGS/GOVERNMENT BUILDINGS

22

Evaluating Power-Demand Reduction With

VFD- Controlled Systems
The pattern of pressure drop through a system during off-design
conditions is critical for centrifugal-pump and fan applications and even
more so for systems employing variable-frequency-drive control.
Typically, the assumption that relative electrical-power demand is changed
following the variation of relative flow rate is made. However, this
assumption is correct only when overall system relative pressure
differential changes in direct proportion to relative flow rate.
By Alexander L. Burd, PhD, PE, and Galina S. Burd, MS

Weil Im Thinking of It ... ................ 5

New Products .............................. 12

News & Notes ................................ 6

Classifieds .................................. 31

Design Solutions ............................ 8

Ad Index ...................................... 32

8&#
8035):
HVAC in Popular Movies: Did Hollywood Get It Right?
HPAC Engineering Editorial Advisory Board member Ron Wilkinson, a
professional engineer who moonlights as a film critic, takes a look at 11
movies and two TV series whose makers were not about to let HVAC fundamentals get in the way of a good story: http://bit.ly/HVAC_Hollywood.

Vintage HVAC Advertisements, 1930

Check out this gallery of vintage advertisements from
1930, the second year of HPAC Engineerings existence:
http://bit.ly/ads_1930.

Calendar of HVACR Training and Education Events

Check out HPAC Engineerings online calendar of upcoming HVACR training and education
events: http://bit.ly/HPACE_Calendar.

AUGUST 2014

HPAC ENGINEERING

Energy spending heating up?

Chill for up to 30% less.
HVAC/R Controller
No eld programming is required. BAS
connectivity via BACnet and modbus
protocols are available.

Altivar 212 Variable Speed Drive

Vary the speed of the condenser fans for
precise condensing temperature optimization.

Magelis STU HMI

Touch screen provides a menu-driven
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the front of the panel.

HP

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Air-Cooled Chillers
The Condenser Fan Pak is shipped pre-programmed,
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of your air-cooled chiller and condenser. Applying
oating high (head) pressure control can reduce
compressor lift, optimize the head pressure per
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Extend the life of your HVAC/R equipment

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Condenser Fan Pak provides you with:

> Easy commissioning and start-up

Condenser Fan Pak from Schneider Electric can reduce the energy

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while extending useful life and reducing life-cycle cost. This solution can benefit
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Calculate your potential energy savings today!

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2014 Schneider Electric. All Rights Reserved. Schneider Electric, Altivar, and Magelis are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. All other
trademarks are the property of their respective owners. LinkedIn, the LinkedIn logo, the IN logo and InMail are registered trademarks or trademarks of LinkedIn Corporation and its affiliates
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*PYJSL

WEIL IM THINKING OF IT ...

BY MICHAEL S. WEIL, EDITORIAL DIRECTOR

EDITORIAL
ADVISORY BOARD:
William G. Acker
Acker & Associates
William P. Bahnfleth, PhD, PE
The Pennsylvania State University
David W. Bearg, PE
Life Energy Associates
Don Beaty, PE, FASHRAE
DLB Associates Consulting Engineers
Lawrence (Larry) Clark, LEED AP O+M
Sustainable Performance Solutions LLC
William J. Coad, PE, FASHRAE
Coad Engineering Enterprises
Peter DAntonio, PE, CEM, LEED AP
PCD Engineering Inc.
Kenneth M. Elovitz, PE, Esq.
Energy Economics Inc.
Ben Erpelding, PE, CEM
Optimum Energy LLC
Alfred E. Guntermann, PE, FASHRAE
Guntermann Engineering LLC
Thomas Hartman, PE
The Hartman Co.
Asif Kadiani, PE, CEM
Hanson Professional Services Inc.
John H. Klote, PE, DSc
Valentine A. Lehr, PE, FASHRAE
Lehr Consultants International
Mark S. Lentz, PE
Lentz Engineering Associates Inc.
Dave Moser, PE, CPMP
PECI
Joel N. Orr, PhD
Orr Associates International
J. Jay Santos, PE
Facility Dynamics Engineering
Andrew J. Streifel, MPH
University of Minnesota
James P. Waltz, PE, CEM, ACFE
Energy Resource Associates Inc.
Gary W. Wamsley, PE, CEM
JoGar Energy Services
Dennis J. Wessel, PE, LEED AP
Karpinski Engineering
Michael K. West, PhD, PE
Advantek Consulting
Ron Wilkinson, PE, LEED AP

Gerald J. Williams, PE, LEED AP

8760 Engineering LLC

What About All The Eye Candy?

e live in an age of instant
gratification. I have numbers to prove it, especially
in the print and online media universe. As the information and data
age matures, the buzz is focused on metrics with regard to online usage in both
the consumer and business-tobusiness community.
We are seeing communications in a state of fluxnewspapers and magazines are
slowly declining. Headlines
in the Aug. 6 issue of the Wall
Street Journal (bit.ly/wsjmedia) points out how media companies such as News
Corp., Gannett, Time-Warner,
and E.W. Scripts are splitting
apart, spinning off their publishing divisions so they can
focus on more profitable and
faster-growing broadcasting
businesses.
And we all know that the television (and even radio) broadcasting world is all about entertainment. Even the news.
Guess whatthe Internet is
as well. Even the news. The metrics I was talking about earlier
are the numbers of people who
come to websites, how long
they stay on those websites, what they read
on those websites, and where they go from
those websites. The bigger the numbers, the
better.
So what does this have to do with the
HVAC Industry? Everything. The websites
that inhabit our sphere are focused on the
business of designing and building mechanical comfort and process systems for our
homes, schools, office spaces, and industrial
plants. Our content is product-based, educational, and useful for the serious business
of designing HVAC systems that create safe
and healthy environments for us to work
and live in.
The operative word here: serious.
Because the mechanical systems industry
is vertically focused, traffic is light, especially
when compared with consumer sites. Does

this mean that maybe were too serious?

Enter the idea of eye candy. No Im not
talking about calendar girls and inappropriate photosIm talking about interactive
games, trivia, and outside-the-box fun that
may only border on useful from a technological standpoint, but are great stress relievers and fun from a humancondition standpoint.
For example, recently Executive Editor Scott Arnold and
Editorial Advisory Board member Ron Wilkinson collaborated
on a video gallery titled, HVAC
in Popular Movies: Did Hollywood Get It Right?
The gallery, found at http://
bit.ly/HVAC-in-movies, points
out the often erroneous depictions of HVAC systems in popular entertainment. It is very
tongue and cheek. It is humorous. It is fun.
And it has garnered an absolute avalanche of traffic. The
metrics went through the roof.
Eye candy.
As fun as that is, we still have
the serious work of educating
and informing our audience.
And that cannot be highlighted
any better than with the stories
that appear in this months issue of the magazine.
From the very technical Evaluating
Power-Demand Reduction With VFD-Controlled Systems (Page 22), to What Owners Need to Know About Duct-Free HVAC
(Page 20), to the ever-important energy
conservation topic covered by Improving
the Efficiency of Small to Mid-Sized Buildings (Page 14), we remain committed to
bringing you the very best, most accurate,
and useful content possible.
So heres the question: from an Internet
perspective, do you like when we have some
fun with galleries like the HVAC in Hollywood gallery? What other fun, out-of-thebox content would you find entertaining?
Engineers need fun too, right? Id love to
hear back from you on the need to balance
between the serious and the eye candy.

Do you like to
see fun things
like the HVACin-Hollywood
video gallery
on HPAC.com?
Or is it all work
and no play?

AUGUST 2014

HPAC ENGINEERING

FROM THE FIELD NEWS & NOTES

EDITED BY SCOTT ARNOLD, EXECUTIVE EDITOR

IFMA Online Benchmarking Portal for

Facility-Management Pros Enhanced
he International Facility Management Association
(IFMA) recently announced enhancements to its
Benchmarks Exchange (BEX) online portal, which
allows facility professionals to compare building data
filtered by industry, facility type, and geographic region.
The improved BEX is said to offer a more streamlined
and expedient way to enter, access, and report data in
the areas of annual facility costs, operations-andmaintenance practices, space, and staffing, with users
now having the ability to:
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complimentary extended access to the reporting function,
which otherwise is available by paid subscription. BEX
can be found online at www.ifma.org/BEX.

Circle 154
6

HPAC ENGINEERING

AUGUST 2014

CODES & STANDARDS

ASHRAE
ASHRAE recently announced the publication of
ASHRAE Guideline 13-2014, Specifying Building
Automation Systems.
Guideline 13 provides background information,
recommendations for good practice, project
considerations, and detailed discussion of options with
respect to the design of building automation systems.
It includes online access to an example specification
that illustrates the concepts described throughout the
document.
Annex D was added
to aid the specification
of performancemonitoring systems.
The guideline
defines three levels of
performance monitoring
and provides criteria
for each level, Dave Kahn, chair of the Guideline 13
committee, said. This allows even the basic systems
to realize some performance-monitoring benefits. It
allows monitoring and reporting of HVAC-equipment
function and operating efficiency, energy
consumption, and environmental conditions. Careful
grouping of X-Y-type plots can provide information
required to monitor and, if necessary, troubleshoot
each different part of the HVAC system. A Level 3
automated fault diagnosis can be used to predict
faults.
In other news, ASHRAE recently announced the
publication of a users manual for ANSI/ASHRAE/IES
Standard 90.1-2013, Energy Standard for Buildings
Except Low-Rise Residential Buildings.
The manual is intended to help users understand
the standards principles and requirements and how to
comply with them. It includes measurements and
calculations in both I-P and SI units.
The book includes sample calculations,
application examples, and references to helpful
resources and Websites. It is suitable for use in
educational programs.
Purchasers of the users manual can download
compliance forms and tools from ASHRAE.org.
The cost of the Standard 90.1-2013 users manual
is $98 for ASHRAE members and $115 for
non-members. The cost of Guideline 13-2014 is $81
for ASHRAE members and $95 for non-members.
Copies can be ordered by phone at 800-527-4723
(United States and Canada) or 404-636-8400, by
fax at 678-539-2129, or online at www.ashrae.org/
bookstore.

ASHRAE Installs Officers,

Directors for 2014-15
SHRAE installed officers
and directors during its 2014
Annual Conference, held
June 28 to July 2 in Seattle.
ASHRAEs president for 2014-15
is Thomas H. Phoenix, PE, principal
and vice president of Moser Mayer
Phoenix Associates in Greensboro,
N.C. His presidential theme is
People, Passion, Performance.
People, passion,
and performance
are three things
that come to mind
when I think about
ASHRAE, Phoenix said. Thanks to
our 53,000 members
around the globe,
Phoenix
ASHRAE is building
a worldwide best-practices network
of innovative people and successful technologies to serve the builtenvironment community. Our membership also has great passion. I
see that in how much time and dedication our people give to helping
write standards, develop research,
guide in policy and procedure, etc.
Together, our people plus their passion ensures performance, whether
thats improving the performance
of our great society or improving
the performance of building stock
around the world.
Also installed for one-year terms
were:
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COTTONWOOD
FILTER SCREENS
Keep Equipment Clean All Season
Long & Simplify Maintenance

Amazingly
Easy to Clean

Quick Release Fasteners For Every Applications

BENEFITS:

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Call 800-819-2869

Visit Our Website: www.airsolutioncompany.com

STOP FOULING OF CONDENSER COILS/COOLING TOWERS & AIR HANDLERS

FROM THE FIELD NEWS & NOTES

Circle 155
AUGUST 2014

HPAC ENGINEERING

FROM THE FIELD DESIGN SOLUTIONS

EDITED BY SCOTT ARNOLD, EXECUTIVE EDITOR

systemsone for the labs and one

for restroomsand complete systems for fire suppression, plumbing,
hydronic heating and cooling, acidwaste piping for the labs, and sheetmetal ductwork.

Design Challenges

The Pharmaceutical & Biomedical Sciences Buildings north side features a floor-to-ceiling
glass curtain wall, which presented design challenges related to perimeter conditioning.

Planning for New Biomedical Facility Puts

Energy Efficiency Under the Microscope
Chilled beams, runaround-loop ERV system included
he first part of a planned research complex, the new Pharmaceutical & Biomedical Sciences Building on Washington State
University (WSU) Spokanes Riverpoint Campus features research and
teaching laboratories, classrooms,
and administrative and faculty offices. Constructing the four-story,
125,000-gross-square-foot facility
was challenging, given the rigid
temperature and humidity set points,
24/7 operation, and high ventilation
rates that were required in a modern
and architecturally pleasing building, Ken Billington, construction administrator with Affiliated Engineers
Inc. (AEI), who oversaw construction and worked with the contracting team to coordinate and complete
installation of the mechanical, electrical, and plumbing systems, said.
Spokanes weather conditions,
when combined with the sleek building facades, required a good amount
of creativity to achieve sustainable
operating costs, Billington, who

HPAC ENGINEERING

AUGUST 2014

works out of AEIs Seattle office, continued. We feel that the end product resulted in a high-performance,
state-of-the-art facility.

Rapid Construction
Work started at the biomed
facility in the summer of 2012 and
finished in November of 2013, Gary
Solberg, project supervisor and manager for Spokane-based mechanicalcontracting and design-build specialist McClintock and Turk Inc., said. It
was a fast-track project, for sure.
To keep pace, Solberg ran two
shifts. For the majority of the project,
McClintock and Turk kept 15 to 20
employees, including plumbers, pipe
fitters, welders, and apprentices, on
the job.
One of our toughest challenges
was packing all the mechanical components into limited ceiling space,
Solberg said. The labs have high
ceilings, further limiting the available space. Yet we needed to install
two separate domestic-hot-water

Among the design challenges the

building presented, two stand out in
Billingtons mind:
t
Conditioned-air delivery. The
floor-to-ceiling glass curtain wall on
the buildings north sideand resulting lack of space to run ductwork
made conditioning the perimeter
difficult. Radiant panelsboth floorand wall-mountedand a radiant
heated/chilled slab help to condition
perimeter spaces.
t
Air balancing. With the potential
for hazardous chemicals and materials in the air, pressure in laboratories
needs to remain negative to prevent
infiltration.
Offset air tracking was incorporated into the buildings design,
Billington said. This ensures proper
pressurization independent of supply/exhaust-air quantities at any
given time due to biosafety-cabinet
and fume-hood operation in the
laboratories. Pressurization remains
constant during all operating phases
of safety-cabinet and fume-hood
operation.
This was especially important at
the buildings lowest level.
An anatomy lab and other specialized lab spaces on this level
were subject to even more stringent
pressurization and air-change rates,
Billington said.

Equipment Selection
During the construction phase,
McClintock and Turk worked with
manufacturer representative Suntoya Corp., which supplied HydroTherm boilers, Taco pumps, expansion tanks, and accessories, and
other key components.
There are two mechanical rooms
in the building: one in the penthouse
dedicated to heating and one in the

Smart buildings run on

Intelligent Equipment.
DYNAMIC DASHBOARDS
System status for owners
and technicians

CONTROL SOLUTIONS
Monitor and control without
the BAS price tag

CONNECTED UNITS
Remote troubleshooting
and maintenance

AUTOMATED
ANALYSIS
System performance
and energy savings

Use advanced Internet of Things technology to connect

rooftops and control HVAC performance 24/7.
Daikin Applied rooftop units, like Rebel, are now using Intelligent Equipment control solutions to
provide real-time data streams for benchmarking performance and monitoring system operation.
Daikin Intelligent Equipment solutions give you an alternative to expensive, traditional, building
automation systems. They provide remote diagnostics and control, reducing operating costs and
improving system reliability.

Daikin Rebel
Rooftop Unit

Learn how you can start making your buildings smarter with Daikin Intelligent
Equipment. Call us at 800-432-1342, or visit DaikinApplied.com.

People and ideas you can trust.

2014 Daikin Applied

Intel Inside is a trademark of Intel Corporation in the U.S. and/or other countries

*PYJSL

FROM THE FIELD DESIGN SOLUTIONS

basement dedicated to cooling. In
the penthouse, six 3-million-Btuh
condensing boilers are piped in
series, assembled in a lead-lag-androtate configuration.
A fin-tube baseboard system
provides supplemental heat to
office spaces and meeting rooms. In
stairwells, wall-mounted radiators
are used. Spread across all floors
of the building, 305 variable-airvolume boxes supply primary heat
to some areas and supplemental heat
to others.
Radiant ceiling panels and infloor radiant tubing heat large
zones, while the latter also provides cooling. A modulating threeway valve responds to outdoor and
indoor conditions for ideal supplywater temperature and draws water
from the boilers or chillers, depending on the need.
From the basement, three 275ton Carrier Evergreen centrifugal
chillers, with cooling towers on the
roof, cool the building via the radiant
system, with more than 300 chilled
beams and coils serving the primary
air-handling systems. The chilled
beams, which are a mix of active and
passive systems, are located throughout the office and laboratory areas.
Radiant ceiling panels are utilized in

Gary Solberg, project supervisor and

manager for McClintock and Turk Inc.,
assembles piping connected to a belowgrade sump pump.
public areas, including the cascading
stairs on the buildings north face.
At full load, the building requires
18,000 MBH in heating mode and
approximately 825 tons of cooling
capacity.

Energy Recovery
In all, the heating and cooling
systems contain approximately 6,000

Chilled-water pumps in the basement mechanical room.

10

HPAC ENGINEERING

AUGUST 2014

gal. of water, a large quantity considering the facilitys size. Given copious
amounts of insulation, that volume
means valuable thermal mass, not
standing heat loss. It also means a lot
of pumping power.
The heating and cooling systems
use 23 large vertical inline pumps
from Taco. Each pump is outfitted
with suction diffusers to conserve
space in the mechanical rooms.
Tacos inline pumps feature a closecoupled design for improved alignment and increased seal life. Flow
rates of up to 2,500 gpm and heads
of up to 300 ft TDH are available for
broad application.
As is the case with most buildings
of this type, and despite the number
of pumps and the large water volume, the amount of energy required
by utilizing pumped energy is substantially less than if fans and air-side
equipment had been used exclusively
to condition the building, Billington
said.
The buildings energy-recovery
loop circulates fluid between two
air streams and captures heat from
the buildings exhaust, redirecting
this energy to offset the heat required
for building ventilation air. This
results in a sensible effectiveness
of up to 50 percent and equates to
significant savings in overall heating
cost.
Because of the potential for hazardous materials in the laboratories and the physical location of the
two air streams being affected, an
enthalpy-wheel energy-recovery
system was not considered. High
air exchange created the need for
energy recovery. A runaround-loop
system was chosen because it has
been proven effective in transferring energy between process loads
(exhaust-air heat) and required
ventilation air while eliminating the
potential for cross-contamination.
Information and photographs courtesy
of Dan Vastyan, an account manager
for Common Ground, a trade-communications firm based in Manheim, Pa.

When Youre the Most Efcient Chiller on the Planet*,

Keeping Your Cool is All in a Days Work.


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*PYJSL

FROM THE FIELD NEW PRODUCTS

EDITED BY CONNIE CONKLIN

Infrared cameras

Torque actuators
Johnson Controls expands its line
of low-torque actuators with two
new models designed to reduce
installation costs.
The M9104-AGP includes a differentialpressure sensor for
exhaust or dualduct VAV applications. It provides
high-accuracy flow
measurement and
reduces installation
costs by self-detecting
positive or negative pressure
on a VAV box. M9104-IUA features line-voltage floating controls.
Where codes permit, it can be
mounted on dampers or valves,
avoiding the need for transformers. Johnson Controls
www.johnsoncontrols.com

Ti90 and Ti95 infrared cameras with wireless connectivity are ideal
for maintenance, troubleshooting, and HVACR technicians, electricians, and facility managers needing to collaborate/share measurements. The cameras deliver quality spatial resolution to conduct
infrared inspections from a safer distance without compromising accuracy. The large 3.5-in. color LCD screen has adjustable brightness for
easy viewing. A removable 8-GB SD memory card or a 8-GB wireless SD card
is included, making camera-sharing simple. AutoBlend and Picture-in-Picture
modes are available in the included SmartView reporting software to easily perform analysis and image adjustments/enhancements. Fluke Corp.
http://en-us.fluke.com/products/infrared-cameras/

Split-coupled end suction pumps

The PACO brand LCS split-coupled end suction pump is suited for liquid transfer
in chilled-water, condenser-water, pressure-boosting, district-heating and cooling, and air-conditioning applications. Its compact design
provides hydraulic performance equal to a frame-mounted,
long-coupled design. Features include a 35-percent
smaller footprint, rapid mechanical-seal access without
motor removal, and faster installation with no baseplate
grouting or coupling alignment. Available in 30 models, the
pump boasts horsepower of up to 125 at 3,500, 1,800, or 1,200 revolutions per
minute. Grundfos
www.grundfos.us

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Certified to GREENGUARD Gold standards for low chemical emissions into indoor air during usage.

Circle 158
12

HPAC ENGINEERING

AUGUST 2014

www.armacell.us | 800.866.5638 | info.us@armacell.com

FROM THE FIELD NEW PRODUCTS

BIM content for heat tracing

Engineered valves
Engineered valves are designed to allow optimum system performance, component-reduction guarantees, and cost savings. Suited
for power generation and energy control, they
are made of steel, brass, stainless steel,
aluminum, or monel. They are used with oil,
air, refrigerant, water, chemicals, fuel, and gases, with sizes ranging from
1/8 in. to 2 in. Fluid Line Products Inc. www.fluidline.com

Commercial gas water heater

The Cyclone Mxi is the first modulating, high-efficiency commercial
gas water heater produced by A.O. Smith. The new modulating
process adjusts the burners firing rate to a specific demand,
which increases energy efficiency and lowers operating costs. All
models are ENERGY STAR qualified, delivering efficiencies of up to
98 percent. The Mxis electronic control with built-in diagnostics
is iCOMM compatible and network-ready for remote monitoring.
Other features include maneuverability and easy installation due
to its lightweight design, a helical-coil heat exchanger that maximizes heat transfer for optimal service life, and the PermaGlas
glass-lining process, which protects the tank against corrosion.
A.O. Smith Corp. www.hotwater.com

FINALLY,

Building information modeling (BIM) content for heat-tracing solutions is a comprehensive suite of new toolsincluding BIM
families and the Raychem Trace-It Revit
add-infor winter safety applications and
hot-water maintenance. With this content,
architects, engineers, contractors, and
building
owners can
easily incorporate
heat-tracing
content
into their
building
models to optimize efficiency and performance. Pentair Technical Solutions
http://pentairthermal.com

an Insulated Saddle System for

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Zero Permeance rated vapor barrier jacketing with Self-Seal tape
Insulation and vapor barrier do not contribute to mold and mildew
Insulation has excellent compressive strength (3.75 PCF and 5 PCF)
Insulation meets rigid 25/50 Flame-Smoke ratings
CFC and HCFC free phenolic foam insulation
Easy Data Sheet, CAD Drawing and Guide Spec Downloads
Unique partial bottom ribbed Saddle secures CoolDry system in place
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AUGUST 2014

HPAC ENGINEERING

13

Improving the Efficiency of

Small to Mid-Sized Buildings

Taking advantage of technological advances
previously limited primarily to large buildings
By CHAD SENGER
Daikin Applied
Minneapolis, Minn.

Over the past few decades, great

t e chnologica l a dv an c es h ave b een
made in HVAC equipment and system
design. These advances, such as variable
airflow, unitary direct digital controls
(DDC), and building energy-management systems, have greatly increased
efficiency and comfort while reducing
energy and operating costs. Todays
high-performance buildings utilize the latest energymanagement strategies for lower utility costs, demandcontrolled ventilation (DCV) for improved indoor-air
quality (IAQ), and Web-based access for troubleshooting,
service, and consistent, reliable comfort.
Unfortunately, these advances have been realized
mainly on higher-tonnage equipment serving large
facilities. Light-commercial facilities, meanwhile, have
remained a largely cost-driven market, with only passing
concern for efficiency and life-cycle cost. However, with
buildings accounting for nearly 40 percent of carbondioxide (CO2) emissions in the United States each year and
an aging electrical grid, there has been renewed focus on
improving the efficiency of even the smallest facilities.
The latest technological advances have made control
and system-integration capabilities available and affordable for small and mid-sized buildings, while providing
functionality similar to that of large building automation systems (BAS). By knowing how to take advantage
of these systems, a variety of savings can be realized
throughout a buildings life.

System Control vs. Thermostat Control

Most commercial buildings utilize packaged HVAC
units because of these systems simplified design and
installation. When installed in a large building, the units

typically are controlled with a buildingcontrol system. In light-commercial

buildings, packaged rooftops and/or
heat pumps are controlled almost
exclusively with thermostats. This is
because thermostats offer the lowest
first-cost solution.
Why would one choose system control
over thermostat control? One reason is
that system controls monitor the status
of all of a buildings HVAC components
and can alert the right people when there
is an issue. Left undiagnosed, small
problems can lead to large energy bills or repair costs. In
a 2004 New Buildings Institute study, 1 91 percent of the
packaged rooftop units tested had at least one problem
that increased cooling energy consumption by 5 to 40
percent (Table 1). Also, a systems approach to control
provides better efficiency and comfort because all system
components can work together to provide superior
control and efficiency. Thermostat controls are, by
nature, decentralized. As a result, scheduling changes
and building checks can be a time-consuming process.
In todays world, facility managers are being asked to do
more with less so it becomes more important than ever
for them to have the right tools to work more efficiently.
Smartphones, for example, have created an expectation

Fault mode

Potential increase in
energy use (percent)

Improper control resulting in overcooling

20

No economizing

10

Failure to switch to minimum-outdoor-air

setting in summer

10

Operation at night

20

Condenser fan/motor failure

15

TABLE 1. The potential increase in energy useand corresponding

potential for energy savingsof various faults and failures.1

Chad Senger is a product manager in the controls group of Daikin Applied. He spent his early career as a warranty administrator
and technical-response specialist for packaged commercial rooftop units and leverages those experiences to support the development of Daikin Applieds unitary and building HVAC controls. In his current role, he works with a network of sales representatives,
technicians, and engineers to provide prepackaged and customized HVAC control solutions for various light-commercial building
applications.
14

HPAC ENGINEERING

AUGUST 2014

A Fresh Approach
to Patient Care
The Titus TLF is uniquely engineered to deliver a more uniform vertical laminar
ow than competitive models. Designed for healthcare and laboratory spaces, the
TLF offers easy access for maintenance and cleaning. TLF exceeds
the requirements for laminar diffusers in ASHRAE Standard
170-2013, and is available in aluminum, 304, and 316
stainless. Titus offers a full range of air distribution
equipment for critical applications, from laminar ow
and radial diffusers to fan lter units for use in cleanrooms.

For details about the TLF, visit www.titus-hvac.com/TLF

or download the Titus AR mobile app and scan this ad.

*PYJSL

IMPROVING THE EFFICIENCY OF SMALL TO MID-SIZED BUILDINGS

Example of an integrated HVAC and controls system for VAV applications.

that most things are remotely accessible via the Web. Why should anything less be expected of a buildings
critical HVAC equipment?

Small-Systems Background
Although the latest generation of
packaged rooftop units is capable
of highly efficient performance,
creating high-performance buildings cannot happen solely at a
unitary level. A systems approach is
the best way to mitigate waste and
drive down energy costs. Todays
small packaged HVAC systems with
integrated controls can affordably
offer most of the control functionality found in larger BAS. Packaged
HVAC solutions, unlike larger BAS,
do not require on-site engineering
or custom programming. When both
equipment and controls come from
the same manufacturer, all of the
components can be programmed
at the factory. This offers a near
plug-and-play option for fast, easy
startup.
Although these first-cost and
installation savings can benefit
contractors, packaged systems also
benefit owners and facilities managers by making their lives easier, their
buildings more efficient, and their
tenants more comfortable. Intuitive
Web-browser-based user interfaces
make navigating a system straight16

HPAC ENGINEERING

AUGUST 2014

forward, while the capability of

automatic discovery of new network
devices makes them more manageable. Through a touchscreen interface, a user can easily review HVAC
operations and building conditions
without having to go up onto the
roof or open up the ceiling.
Designing high-performance
buildings utilizing system-level
HVAC control enables the application of energy-saving options, such
as:
t
Variable air volume (VAV).
Constant-volume bypass systems
historically have been the system
solution of choice for small-building

HVAC because of their ability to control at a zone level without the use
of variable-frequency drives (VFDs).
However, they were not designed for
efficiency, as fans always run at top
speed, and efficiency plummets as
the temperature of the recirculated
air entering a unit decreases. For
these reasons, Title 24 of the California Code of Regulations proposes a
ban on bypass ducts, eliminating the
energy credits associated with their
zoned performance. With the cost of
VFDs decreasing, eliminating the bypass system altogether now is possible and not only increases efficiency,
but significantly reduces the cost of
ownership. It is estimated that VAV
systems use roughly 60 percent of the
airflow of their bypass counterparts.
t
Scheduling. Proper HVAC equipment scheduling can result in huge
energy savings for a building. Equipment controlled by decentralized
systems (thermostats) typically are
not scheduled optimally. In many
cases, they run continuously, resulting in an estimated 20-percent premium of the annual electricity bill.
Centralized scheduling, with features
such as optimal start and scheduled
holidays, reduces run time while
eliminating waste.
t
Supply-temperature reset. With
system-level coordination, advanced
control routines can utilize zone-

Traditional non-communicating HVAC system

Integrated HVAC and control system

No external alarm indication for maintenance

personnel, so alarms persist, wasting energy.

Central alarm access for all components and

text or e-mail alerts.

No central control for setpoint and

configuration changes.

Remote access to view and control the system

using a Web browser or laptop, smartphone,
or tablet.

Every HVAC component on its own schedule

with no coordination between devices.

Centralized scheduling and coordination ensures

equipment schedules match the occupancy of the
building and operate only when needed.

No information on operation history.

Graphical trending to identify operating

tendencies, alarm diagnostic information, and
opportunities for improvement.

Hard-wired control signals that are expensive

and labor-intensive to install.

Simple daisy-chain communication wiring for

networking components for faster, less expensive
installation.

Unit troubleshooting requires a ladder and

ceiling access, as well as a possible long drive
to a job site.

Easy-to-use touchscreen interface to all system

components for convenient troubleshooting
on site or Web access for remote troubleshooting.

Integrating a buildings HVAC system(s) with a building automation and control system offers
numerous benefits.

IMPROVING THE EFFICIENCY OF SMALL TO MID-SIZED BUILDINGS

operating conditions by
level information to optimize
monitoring trend informarooftop-unit performance.
tion. This information access
Supply-temperature-reset
can allow facility personnel to
strategies allow rooftop units
provide temporary relief and
to reduce cooling energy
ensure maintenance personuse based on factors such
nel have the right parts and
as outside-air temperature,
tools for job-site trips, minireturn-air temperature, or
mizing maintenance costs.
worst-case zone. However,
Todays small systems can
supply-temperature reset
send e-mail or text messages
can cause increased fan and
to support personnel when
reheat energy on VAV sysalarm conditions exist, giving
tems, so this should be conthem advanced warning of a
sidered before utilizing this
A Web-browser-based control system allows remote access to
potential problem.
type of control strategy.
t
Pressure reset. A pres- system status and control points using any device with a browser,
Benefits of Packaged
sure-reset strategy adjusts such as a smartphone, tablet, or laptop.
Systems
the duct-pressure setpoint
t
Demand response/peak shaving.
With building controls
on VAV systems based on
Premium rates resulting from elecoffering superior efficiency, remote
the worst-case zone. The logic contricity use during peak-demand times
access, and the ability to resolve
tinually drives the duct-pressure setcan represent a substantial portion of
maintenance headaches, why would
point (and fan energy) down until one
the energy bills of commercial buildanyone construct a building withzone damper opens approximately
ings. Also, energy use during this
out specifying them? The answer
100 percent. At this point, the system
time overburdens the nations aging
is simple: first-cost concerns. BAS
is providing the minimum amount
electrical grid, which has given rise
have a reputation for being expenof cold air to the ductwork needed
to the concept of demand response.
sive, complicated, and only necessary
at any particular moment without
Demand response is a request
for larger facilities or campuses. As
starving any of the zones. This
from a utility to reduce a buildings
discussed, however, small-building
optimization technique can yield fan
energy use for a period of time.
systems with integrated controls
energy savings of roughly 30 to 50
Responding to these requests can
offer most of the functionality of a
percent over typical fixed-pressure
save a building owner significant
BAS at a fraction of the cost.
setpoints. The pressure reset also satmoney and provide rebate opportuniAdditionally, packaged systems
isfies ANSI/ASHRAE/IES Standard
ties. A system-level HVAC approach
are pre-engineered, so they can
90.1, Energy Standard for Buildings
is far and away the best method of
be implemented with confidence.
Except Low-Rise Residential Buildimplementing demand-response
This eliminates integration hassles,
ings, and Californias Title 24, which
requests from a power company befinger pointing, and disputed payboth require this level of building
cause thermostats are not equipped
ments when it is time to turn over a
control with DDC at the zone level.
to provide this level of control. Also,
building. When an issue does arise,
t
DCV. In most cases, outside air
systems can implement advanced
is much more expensive to condition
strategies, such as pre-cooling, to rethan recycled building air. Typically,
duce the temperature of the thermal
energy savings can be realized by
mass in a building, thereby reducminimizing fresh air, but ventilation
ing the additional cooling required
requirements can change dramatiduring these afternoon peak times.
cally. Tracking occupancy changes
t
Alarm/fault management.
via occupancy or CO 2 sensors and
tailoring the amount of fresh air
Energy-management systems give
introduced into a building (or a specustomers an early indication of
cific zone) ensures good IAQ while
improper operation. This allows
minimizing energy use. DCV is espethem to proactively address issues
cially effective for spaces with high
before a hot call is initiated by a
E-mail or text messages can be sent from a
occupancy diversity, such as schools,
tenant. Remote access to critical
system to alert facility managers or service
churches, and courthouses, in which
HVAC components allows facility
contractors that operating conditions are
cases it may offer up to 50 percent
personnel to change setpoints,
outside performance parameters.
additional energy savings.
clear alarms, or identify improper
AUGUST 2014

HPAC ENGINEERING

17

IMPROVING THE EFFICIENCY OF SMALL TO MID-SIZED BUILDINGS

Todays technologically advanced light-commercial rooftop units include

energy-saving features typically available only on larger units: energyrecovery wheels, digital controls, variable-speed inverter compressors,
and electronically commutated fan motors.

the system manufacturer can quickly

troubleshoot components along with
the control logic that governs them.
Finally, packaged systems can be
preconfigured at the factory. This
means near plug-and-play startup
and implementation on the job site by
the mechanical contractor. By comparison, custom BAS require days, if
not weeks, of on-site programming.

Conclusion
Americans spend 90 percent
of their time indoors. They usually

spend most of their

days going from one
building to the next, and most
of those buildings are not large,
multistory facilities. They are small
offices, convenience stores, community centers, and retail buildings.
The very same issues that drive the
incentive to provide efficient HVAC
solutions to larger facilities also exist
with smaller buildings. In practice,
however, there is less concern when
it comes to designing small buildings for efficiency and life-cycle costs
(normally the price tag is the driving factor and the lone purchasing
decision), a practice that ultimately
costs owners and tenants for the life
of buildings. Today, highly efficient

packaged and pre-engineered systems minimize design and control

costs. Existing technology is now
affordable to make all buildings highperformance buildings by simply
changing our expectations and the
approach we take in designing the
HVAC in these facilities.

Reference
1) Roth, K., Westphalen, D., Dieckmann, J., Hamilton, S., & Goetzler,
W. (2002, July). Energy consumption
characteristics of commercial building HVAC systems volume III: Energy
savings potential. Table presented at
the Buildings Technology Program
of the United States Department of
Energy.

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very cooling tower has its unique dirt
conditions, space constraints and
other special characteristics. Filtration
systems must take these into account in
order to maintain particle free water.
Orival filters are versatile enough to
meet these criteria. They remove a wide
range of dirt down to micron size, of any

specific gravity, even lighter than water.

Typical examples include: airborne particles, microbiological growth, bugs,
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Line pressure powered, they permit use
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Circle 161

18

HPAC ENGINEERING

AUGUST 2014

seconds and does not interrupt flow.

Reclaim units recirculate rinse water
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assistance, contact: Orival, Automatic SelfCleaning Filters, 213 S. Van Brunt St.,
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ENGINEERING ADVANTAGE

What Owners Need to Know About

Duct-Free HVAC
Seven key characteristics of variable-refrigerant-flow zoning systems
By PAMELA ANDROFF, PE, LEED AP
Mitsubishi Electric US Cooling & Heating Division
Suwanee, Ga.

The fastest-growing segment of the U.S. HVAC market, variable-refrigerant-flow (VRF) zoning is a flexible,
cost-effective, and environmentally friendly HVAC option
for commercial buildings with multiple floors and areas.
VRF zoning provides precise comfort control by moving
refrigerant through piping to zones in need of cooling
or heating. Some VRF zoning systems cool and heat
simultaneously, providing personalized comfort to each
zone or space regardless of time of day, sun or shade,
season, or special requirements. This article discusses
seven primary characteristics of VRF zoning technology.

Energy Efficiency
With conventional HVAC systems, central equipment
generates sizable capacity, which is delivered via largevolume ducting to an entire floor or building. Fixed-speed
compressors in conventional HVAC systems typically
operate at full power. In the United States, however, zones
exhibit partial-load conditions more than 90 percent of
the time. Conventional systems cannot handle partial
loads, resulting in energy fluctuations and poor set-point
satisfaction.
VRF zoning systems with electric inverter-driven
compressors offer full-range variable capacity, delivering
only the amount of conditioned air needed for a
zone. Working in tandem with integrated controls
and sensors, the compressors seamlessly adjust speed
to maintain desired capacity. This function, along with
ductless design, typically makes VRF zoning systems
about 30 percent more energy-efficient than conventional
systems, which lose energy through ductwork.
VRF zoning systems can help facilities to meet ENERGY
STAR, Green Globes, and LEED (Leadership in Energy
& Environmental Design) requirements and achieve the
highest integrated-energy-efficiency-ratio (IEER) ratings.

Temperature Control and Energy Monitoring

Load diversity. A VRF zoning system manages different
areas of a building based on diversity of load and usage.
It adjusts capacity as space loads change and people move
about or as the sun moves across the building throughout
the day. With load diversity, the total applied capacity
of selected air handlers (indoor units) can be up to 150
percent of the capacity of the compressor (outdoor unit).
Intelligent sensor technology. Intelligent indoor-unit
sensors measure room air temperature at the return or
at a remote controller or wall sensor. Advanced linear
electronic expansion-valve technology ensures delivery
of the precise amount of refrigerant needed to meet each
zones load at a given time. Some VRF zoning systems
feature sensor technology that compares air and floor
temperatures and adjusts coil temperature as needed to
optimize comfort within a space.
Intuitive system control. Select VRF zoning systems
can cool or heat up to 50 zones. Networked control
options allow for the management of a buildings HVAC
system down to the indoor-unit level. Capabilities
include occupancy sensing, dual temperature set point
and setback, mode scheduling, the ability to integrate
third-party equipment, storage of maintenance data,
and energy-monitoring functions with tenant billing of
system energy consumption. Central controllers support
interconnection with a networked PC on a local-area
network for convenience of monitoring and operation.
Other control networks support integration with building
management systems for wider system control.

Heat Recovery
Some VRF zoning systems offer highly responsive
simultaneous cooling and heating, which maximizes the
heat energy absorbed from a space, heat energy that
otherwise would be expelled outdoors. The system takes
heat energy removed from a zone in cooling mode and
applies it to a zone calling for heat. By bypassing the
outdoor unit, the system runs in its most efficient state.

Pamela Androff, PE, LEED AP, is product manager, commercial and product planning, for Mitsubishi Electric US Cooling &
Heating Division. In 2013, she became the youngest person and fourth female to serve as president of ASHRAEs Atlanta chapter,
which she also has served as secretary and treasurer. She has a bachelors degree in mechanical engineering from the University
of Central Florida, where she served as president of the ASME chapter.
20

HPAC ENGINEERING

AUGUST 2014

Life-Cycle Costs
VRF zoning systems tend to have
fewer components than conventional
HVAC systems, reducing equipment
costs, complexity, and installation
time. Also, VRF zoning systems use
less refrigerant and have fewer electrical connections. They use built-in
logic that modifies behavior to maximize performance, whereas many
other systems require retrocommissioning and constant maintenance
to preserve installed efficiency. This
means greater comfort and longer
system life. Many VRF zoning systems require only filter cleaning, an
additional cost savings over conventional industry models that call for
disposable-filter replacements.

Installation
A VRF zoning system is easily
adaptable as the needs of a building
change, especially with the rotation
of commercial office tenants, who
have specific cooling and heating
needs. Indoor units can be added
and subtracted easily, with minimal
interruption of system operation.

MORE ON VRF ZONING

Zoning Remedy for Long-Dormant Sick Building,
r Variable-Refrigerant-Flow
April 2014, http://bit.ly/Mitsubishi_0414.
r Combining DOAS and VRF, Part 2 of 2, April 2014, http://bit.ly/
Bowers_0414.
r VRF Zoning Helps School District Achieve Energy- and Cost-Saving Goals,
November 2013, http://bit.ly/Mitsubishi_1113.
Variable-Refrigerant-Flow
Zoning System Helps Protect Museums Nerve
r
Centers, February 2013, http://bit.ly/Mitsubishi_0213.

are available in air- or water-source

variety with a wide range of capacities. Sound levels range from 24
dB(A) to 65 dB(A)equivalent to an
electric shaver.

Ventilation Air
Many VRF-zoning manufacturers
offer ventilation products that integrate into the same controls network
as indoor units. Dedicated outdoorair systems (DOAS) can process
100 percent of outdoor air. Energy-

recovery ventilators (ERV) can be

used in tandem with VRF zoning
systems to temper ventilation air. Exhaust air passes incoming ventilation
air, providing a heat exchange that
allows the incoming air to be heated
or cooled to achieve neutral temperatures. Both ERV and DOAS can be
monitored via the controls system.
Did you find this article useful? Send
comments and suggestions to scott
.arnold@penton.com.

CC-140 CoilPro

Aesthetics
VRF zoning systems help to maintain a buildings interior design with:
t
Discreet indoor units: Indoor
VRF units are compact and available
in multiple styles. Designed to blend
into their environments, they can
be installed in many different locations. Ductless options include wallmounted, floor-standing (exposed
and concealed), ceiling-recessed
cassette, and ceiling-suspended.
Ducted options include vertical
concealed and ceiling-concealed.
Ductless options in particular free
up valuable interior space and enable
increased ceiling height. Sound levels range from 19 dB(A) at low speed
to 49 dB(A) at high speedquieter
than a refrigerator.
t
Compact outdoor units: Modular outdoor units are easy to install
and can be tailored to almost any
building, including being placed on
a roof. Many VRF zoning systems

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HPAC ENGINEERING

21

&WBMVBUJOH

Power-Demand Reduction With

7'%$POUSPMMFE
4ZTUFNT
The impact of relative dynamic-pressure
losses and other factors on overall
power demand and energy savings
By ALEXANDER L. BURD, PhD, PE, and GALINA S. BURD, MS
Advanced Research Technology
Suffield, Conn.

The pattern of pressure drop through a system during

off-design conditions is critical for centrifugal-pump
and fan applications and even more so for systems
employing variable-frequency-drive (VFD) control.
Typically, the assumption that, based on the affinity
laws, relative electrical-power demand is changed
following the variation of relative flow rate, which
is raised to the power of 3, is made. However, this
assumption is correct only when overall system relative
pressure differential changes in direct proportion to
relative flow rate, which is elevated to the power of 2.
Overall pressure drop in a system could be presented
as consisting of:
t
'SJDUJPO
QSFTTVSF
MPTTFT
t
-PDBM
SFTJTUBODF
MPTTFT
t
4UBUJD
PS
IFBE

QSFTTVSF
MPTTFT
Pressure losses, including friction and local resistance
losses, are variable and depend on the velocity of the fluid
travelling through a pipe or duct, while static-pressure
losses (i.e., vertical elevation loss to lift fluid to a point of
utilization and/or minimum required pressure differential
at a terminal unit, etc.) could be assumed constant and
independent of fluid velocity. We combined friction and
local resistance pressure losses into a single category:
dynamic pressure losses. This assumption is convenient
for the analysis applied in Figure 1.
Figure 1 demonstrates how the ratio between the

relative (dimensionless) design dynamic and staticpressure loss impacts overall relative pressure drop in
a closed-loop system, which, in turn, influences system
power demand. For convenience, we assumed the curve
of the system in Figure 1A (for the quadratic relation
between pressure drop and flow rate) would go through
the origin. The graphs in Figure 1 were built on the
assumption the VFD would have a turndown ratio (TDR)
of 10 to 1, which is typical of VFDs. This was done by
varying the speed of the electrical motor via the changed
electrical-power frequency from 60 Hz to 6 Hz. This meant
the ratio of current flow rate to design flow rate (the
relative flow-rate ratio [RFR]) would vary from 1.0 (design) to 0.1 (minimum). We further assumed the installed
horsepower of the electrical motor and VFD would match
UIF
TZTUFN
EFTJHO
MPBE
4ZTUFN
SFMBUJWF
QSFTTVSF
MPTTFT

(P4:4) were calculated from the following equations:
(1)
P4:4
%&4

4031-%&4

%31-%&4

431-%&4) = 1.0
P4:4
$63

4031-$63

%31-$63

431-$63


4031-%&4
(2)
%31-$63

%31-%&4 RFRn=2
(3)
431-$63

431-%&4 RFRn=0
(4)
where:
P 4:4
%&4 = system relative pressure losses at design
conditions
4031-%&4 = system overall relative pressure losses at
design conditions
%31-%&4 = system relative dynamic pressure losses at
design conditions
431- %&4 = system relative static-pressure losses at
design conditions
P4:4
$63 = system relative pressure losses at current
conditions
4031- $63 = system overall relative pressure losses

Alexander L. Burd, PhD, PE, is president of, and Galina S. Burd, MS, is a project manager for, Advanced Research Technology
(www.energyart.net), an engineering and research consulting firm with offices in Suffield, Conn., and Green Bay, Wis. Alexander
(aburd@energyart.net) has 35 years of experience in the design, research, and optimization of HVAC and district energy
systems, which includes publication of more than 35 research and technical papers in American and European journals,
while Galina (gburd@energyart.net) has more than 25 years of design and research experience in the HVAC and architecturalengineering field and has co-authored many technical and research papers in American journals. Alexander and Galina have
co-authored three U.S. patents related to energy conservation.
22

HPAC ENGINEERING

AUGUST 2014

at current conditions
DRPLCUR = system relative dynamic pressure losses at
current conditions
SRPL CUR = system relative static-pressure losses at
current conditions
n
= exponential index parameter varying from 0 for
relative static system pressure losses to 2 for relative
dynamic system pressure losses

System overall relative

pressure losses, PSYS

Although dynamic pressure losses follow relative

changes in flow rate elevated to the power of 2, system
overall pressure losses consisting of both dynamic- and
static-pressure components do not. There are, however,
two exceptions: the theoretical cases of systems with no
dynamic pressure losses (SRPLDES = 1.0; DRPLDES = 0.0)
or no static-pressure losses (DRPL DES = 1.0; SRPL DES =
0.0). These cases are shown by Line 6 and Curve 7, respectively, in Figure 1A. The rest of the curves between
Line 6 and Curve 7 are related to relative design dynamic
1.0

System overall relative factor

parameter (SFP) to match actual
pressure losses (PSYS)

PSYS = SORPLCUR SORPLDES = RFRSFP

0.8
0.6
0.4
0.2
0.0
0.0

0.1

0.2

0.3

0.4
0.5
0.6
System relative ow rate, RFR
3. DRPLDES = 0.5; SRPLDES = 0.5
4. DRPLDES = 0.3; SRPLDES = 0.7

0.7

0.8

0.9

1.0

5. DRPLDES = 0.1; SRPLDES = 0.9

6. DRPLDES = 0.0; SRPLDES = 1.0

B. System relative ow rate and factor parameter to match actual pressure losses; SFP = f(RFR)
1.6
1.2
0.8
0.4
0.0
0.1

0.2

0.3

1. DRPLDES = 0.9; SRPLDES = 0.1

2. DRPLDES = 0.7; SRPLDES = 0.3

0.4
0.5
0.6
System relative ow rate, RFR
3. DRPLDES = 0.5; SRPLDES = 0.5
4. DRPLDES = 0.3; SRPLDES = 0.7

0.7

0.8

0.9

1.0

C. System relative ow rate and power-demand reduction factor; PDRF = f(RFR)

2.0
1.0
0.1

0.2

1. DRPLDES = 0.9; SRPLDES = 0.1

2. DRPLDES = 0.7; SRPLDES = 0.3

0.3

0.4
0.5
0.6
System relative ow rate, RFR
3. DRPLDES = 0.5; SRPLDES = 0.5
4. DRPLDES = 0.3; SRPLDES = 0.7

1. Required system factor parameter to

match actual overall pressure losses
2. Required system factor parameter to
match actual overall pressure losses
3. Required system factor parameter to
match actual overall pressure losses
4. Required system factor parameter to
match actual overall pressure losses
5. Required system factor parameter to
match actual overall pressure losses
6. System SFP = 2

5. DRPLDES = 0.1; SRPLDES = 0.9

6. DRPLDES = 1.0; SRPLDES = 0.0

3.0

0.0
0.0

1. System overall relative pressure losses

2. System overall relative pressure losses
3. System overall relative pressure losses
4. System overall relative pressure losses
5. System overall relative pressure losses
6. System overall relative pressure losses
7. System overall relative pressure losses
at SFP of 2
7. System relative pressure losses are equal to
relative ow rate raised in power of 2 (SFP = 2)

2.0

0.0

(5)

Equation 5 allows the magnitude of SFP for various

combinations of P SYS and RFR, which are shown in
Figure 1A, to be found. Figure 1B demonstrates how

A. System relative ow rate and pressure losses; PSYS = f(RFR)

1. DRPLDES = 0.9; SRPLDES = 0.1

2. DRPLDES = 0.7; SRPLDES = 0.3

System overall relative powerdemand reduction factor, PDRF

pressure losses (DRPL DES) varying from 0.9 to 0.1 and

relative design static-pressure losses (SRPLDES) varying
from 0.1 to 0.9. Figure 1A indicates the system overall
relative pressure drop (PSYS) could deviate significantly
from the theoretical assumptions. For instance, for the
system with DRPL DES of 0.9, P SYS varies from 1 to 0.1
when RFR varies from 1 to 0.1. On the other hand, for the
system with DRPLDES of 0.5, PSYS varies only from 1 to 0.5
when RFR varies from 1 to 0.1.
In the following analysis, we introduced system factor parameter (SFP), which indicates overall functional
dependency between system pressure loss and flow rate.
The following equation was utilized:

0.7

0.8

0.9

1.0

1. Actual to theoretical power-demand

reduction factor
2. Actual to theoretical power-demand
reduction factor
3. Actual to theoretical power-demand
reduction factor
4. Actual to theoretical power-demand
reduction factor
5. Actual to theoretical power-demand
reduction factor
6. System PDRF = 3

5. DRPLDES = 0.1; SRPLDES = 0.9

6. System relative power-demand reduction factor is equal to
relative ow rate to be raised in power of 3 (PDRF = 3)

Notes:
1. Variable-frequency-drive (VFD) turndown ratio assumed to be 10 to 1.
2. VFD horsepower and electrical-motor horsepower assumed to be equal to design magnitudes.
3. System horsepower safety factor equal to 1.0 (SF = 1.0).

FIGURE 1. System relative-pressure-drop impact on power-demand-reduction factor.

AUGUST 2014

HPAC ENGINEERING

23

EVALUATING POWER-DEMAND REDUCTION WITH VFD-CONTROLLED SYSTEMS

the actual value of SFP in Equation 5 depends on the

system-pressure-drop-distribution pattern between
design dynamic and static components of the pressure
loss described earlier. SFP represents the average
weighted magnitude of the exponent in the equation,
which should be applied to relative flow rate to match
system relative pressure drop. The top straight line in
Figure 1B (No. 6) represents the theoretical case in which
system pressure losses are caused by dynamic losses
only, which is equivalent to an exponent value of 2
(SFP = 2). This straight line correlates to Line 7 in Figure
1A. The rest of the curves in Figure 1B represent various
combinations of system dynamic and static losses and are
correlated to curves 2 through 6 in Figure 1A. The Figure
1B curves indicate SFP values could vary substantially to
match system relative pressure drop and could be well
below the theoretical value of 2, which typically is utilized
in engineering designs with VFD applications.
Figure 1B also demonstrates the SFP does not remain
constant and varies depending on the ratio of relative
design dynamic-pressure losses to static-pressure losses,
as well as RFR. Figure 1B shows the usual control strategy
of maintaining design pressure differential at an RFR of
1.0 could be improved by resetting the controlled pressure

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Circle 164
24

HPAC ENGINEERING

AUGUST 2014

differential as a function of RFR.

Accepting the theoretical case as the design baseline
might lead, as shown in figures 1B and 1C, to overestimating magnitudes of potential energy savings associated
with VFD applications.
The field areas between Line 6 and the five other curves
in Figure 1B show the potential reduction in system
relative pressure losses. The greater the magnitude of
design system relative static-pressure losses, the larger
the field areas.
Similarly, Figure 1C shows system overall relative
power-demand reduction ratio (PDRR) as compared with
the theoretical value of 3. System PDRR will be in direct
proportion to the variation in system relative pressure
differential (Figure 1B) and RFR. Line 6 in Figure 1C represents the theoretical PDRR of 3 for the case in which all
pressure losses are caused by dynamic losses (correlated
with Curve 7 and Line 6 in Figure 1A and 1B, respectively).
The other five curves in Figure 1C outline PDRR for various distribution patterns between relative design dynamic
and static-pressure losses. Thus, the field areas between
Line 6 and each of the other curves represent the reduction in available power-demand savings for various operational loads, which correlate with respective RFR values.
Once again, the higher the magnitude of system relative
static-pressure losses, the larger the field areas between a
theoretical value of 3 and actual PDRR.
Assuming the efficiency of an electrical motor and
pump or fan remains constant, the calculation of system
relative power demand (RPD) could be simplified. When
combined with PSYS from Equation 5, the magnitude of
RPD could be presented as follows:
RPD = PSYS RFR1.0 = RFRSFP RFR1.0 = RFRPDRF

(6)

where:
PDRF = SFP + 1 = system power-demand reduction
factor
Equation 6 allows the magnitudes of PDRF (shown in
Figure 1C) for various combinations of PSYS (shown in
Figure 1A) and RFR to be found.
For the system with dynamic pressure losses only, the
theoretical PDRF will be 3. For the systems having both
dynamic and static-pressure losses, the PDRF will be less
than 3.
PDRF could vary from 2.8 at an RFR of 0.99 for a
DRPLDES of 0.9 (Curve 1 in Figure 1C) to 1.96 at an RFR of
0.1. Thus, for this system, the PDRF magnitude compared
with its theoretical value of 3 could be overestimated by
as much as 43.3 percent on average over the course of
a year, assuming equal-weight-time-distribution occurrences at various loads from an RFR of 1.0 to an RFR of
0.1. Utilizing the same approach for the systems with a
DRPLDES of 0.7 (Curve 2 in Figure 1C) and 0.5 (Curve 3 in

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26

HPAC ENGINEERING

AUGUST 2014

3.0
2.0
2.5

Relative average annual system powerdemand reduction factor, PDRF

1.5

2.0
1.5

1.0
Relative average annual
system parameter factor, SFP

1.0

0.5
0.5

Relative average annual system power-demand

reduction factor, PDRF

3.5

2.5

0.0

0.0
0.0

0.1

0.2

0.3
0.4
0.5
0.6
0.7
0.8
System relative dynamic pressure losses, DRPLDES

0.9

1.0

1.1

Note: System safety factor (SF) = 1.0

FIGURE 2. Relative average annual system SFP and PDRF as a function of DRPLDES
magnitude.
its maximum speed. Furthermore,
under this scenario, the system VFD
TDR of 10 to 1 will be reduced to 6.8
to 1, or lowered by 32 percent.

If we assume a safety factor of 2.0

for an electrical motor and a VFD,
then the design load will be satisfied
when the electrical motor runs near

A. System safety factor and VFD turndown ratio

System VFD turndown ratio, TDR

12.0
10.0
8.0
VFD turndown ratio

6.0
4.0
2.0
0.0
1.0

1.1

1.2

1.3

1.4
1.5
1.6
System safety factor, SF

1.7

1.8

1.9

2.0

1.9

2.0

Notes:
1. VFD turndown ratio at a SF of 1.0 is assumed to be 10 to 1.0.
2. System DRPLDES = 1.0.

B. System safety factor and VFD relative speed

120
System VFD relative maximum and
minimum speed, percent

Figure 1C), the reduction in potential annual power-demand savings

as compared with the theoretical
case could be as high as 130 percent
and 216 percent, respectively.
Figure 2 shows the variation in relative average annual SFP and PDRF
as a function of DRPLDES magnitude.
SFP varies from 2 (theoretical case) at
a DRPLDES of 1.0 to 0.3 at a DRPLDES
of 0.1. This again demonstrates how
significant deviation from a theoretical case could be. Figure 2 also shows
that, for the considered conditions,
PDRF deviates quite noticeably from
its theoretical value of 3 at a DRPLDES
of 1.0 to 1.3 at a DRPLDES of 0.1.
This analysis was conducted for
the conditions under which the electrical motor and VFD were sized to
match system design load. However,
often, an electrical motor and a VFD
are sized with safety factors (or load
factors), especially for industrial and
commercial applications.
Safety factors also are applied
to compensate for VFD-capacity
derating conditions precipitated by
a deviation from given optimal
switching frequency for a drive,
VFD-enclosure cooling air temperature, etc. In these instances,
derating conditions might reduce a
drives output current, which would
require utilization of oversized
drives. Designers quite often oversize electrical-motor horsepower
to increase system reliability and
redundancy. Typically, system safety
factors vary from 1.0 to about 2.0.
Figure 3 shows the correlation
between system VFD TDR (Figure
3A) and VFD maximum and minimum speed (Figure 3B) for five
safety factors. For example, at a TDR
of 10 to 1 (safety factor of 1.0), the
system VFD maximum and minimum
speed will be 100 percent and 10
percent, respectively. For instance,
if the safety factor for both an electrical motor and a VFD is 1.33 when
DRPL DES is 1.0, then the system
design load will be satisfied when
the electrical motor is running at 91
percent, instead of 100 percent, of

Relative average annual system parameter factor, SFP

EVALUATING POWER-DEMAND REDUCTION WITH VFD-CONTROLLED SYSTEMS

100
VFD maximum speed
80
60
40
VFD minimum speed

20
0
1.0

1.1

1.2

1.3

1.4
1.5
1.6
System safety factor, SF

1.7

1.8

Notes:
1. VFD turndown ratio at a SF of 1.0 is assumed to be 10 to 1.0.
2. System DRPLDES = 1.0.

FIGURE 3. System safety factor, VFD turndown ratio, and relative maximum and minimum
speed.

*PYJSL

EVALUATING POWER-DEMAND REDUCTION WITH VFD-CONTROLLED SYSTEMS

28

HPAC ENGINEERING

AUGUST 2014

1. Annual electrical-energy-usage increase value at SF of 1.0

2. Annual electrical-energy-usage increase value at SF of 1.33
3. Annual electrical-energy-usage increase value at SF of 1.5
4. Annual electrical-energy-usage increase value at SF of 1.65
5. Annual electrical-energy-usage increase value at SF of 2.0

4.5
System relative annual electricalenergy-usage increase factor

80 percent of its maximum speed.

For these conditions, the system VFD
TDR of 10 to 1 will be reduced to 4 to
1, or lowered by 60 percent.
Figure 4 demonstrates (for steadystate operational conditions) the impact of system relative dynamic-pressure losses on magnitude of potential
overestimation of annual electricalenergy savings. The assumption for
the baseline conditions (Line 1) was
that, at a DRPL DES of 1.0, the same
magnitude of safety factor (1.0) will
be applied for the electrical motor
and VFD. Figure 4 indicates the
application of the safety factor could
decrease potential annual powerdemand reduction and electricalenergy savings compared with the
theoretical case. The reduction in
power demand and energy savings
depends on the rate of increase of
safety factor. This savings reduction
will occur for safety-factor values
ranging from 1.33 to 1.65. Above this
magnitude, the rate of reduction in
savings will remain constant. This
happens because at this point, any
further increase in safety factor will
reduce potential rate of increase
of electrical savings at lower VFD
speeds because of reduced VFD TDR.
The impact of safety factor still
could be quite substantial. For instance, Figure 4 depicts the increase
in annual electrical-energy use with a
DRPLDES of 0.5 and a safety factor of
2.0 could be 22.5 percent compared
with the system with a safety factor
of 1.0. However, this impact will diminish at higher values of DRPLDES.
Figure 4 could be used to evaluate
magnitude of relative annual energy
savings for VFD applications compared with the theoretical baseline
case. For instance, for the system
with a DRPL DES of 1.0 and a safety
factor of 1.0, the energy savings at
the average relative annual load of
0.55 (i.e., [1 + 0.9 + 0.8 + 0.7 + 0.6 +
0.5 + 0.4 + 0.3 + 0.2 + 0.1] 10) will
yield a reduction factor of 6 (i.e., 1/
[0.55 3 ]) as compared with the system with no VFD control. However,
for the system with a DRPLDES of 0.7

4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5

0.6

0.7

0.8

0.9

1.0

System dynamic relative pressure losses, DRPLDES

Notes:
1. The impact of VFD and electrical-motor efciency values is not considered.
2. VFD and electrical-motor efciencies: VFD and MOT should be applied for the particular VFD and
motor applications to the data shown.
3. Electrical-energy relative annual usage increase compared to theoretical case with DRPLDES of 1.0 and SF of 1.0.

FIGURE 4. System annual electrical-energy use, dynamic relative pressure loss, and safety
factor.
and a safety factor of 1.0, the energy
savings will produce the diminished
reduction factor of 2.6 (i.e., 6 2.3)
because of the increase in relative
annual electrical-energy use (Figure
4). Furthermore, if in addition to the
latter conditions, the system safety
factor will increase to 1.65, then the
annual energy savings will yield the
lower reduction factor of 2.2 (i.e., 6
2.7) compared with the system with
no VFD control (Figure 4). Thus, the
theoretical annual electrical-energy
savings will exceed their actual value
by the factor of 2.7 (i.e., 6 2.2).
Because VFD efficiency losses
vary approximately in direct proportion to VFD horsepower load, any
increase in electrical load for the
system with a DRPLDES of less than
1.0 and a safety factor greater than
1.0 might lead to reduced VFD efficiency and increased power demand
at off-design operational conditions.
This should be considered during
system design.

System With VFDCVFD Bypass

Power-Demand Control for
Electrical Motors
It is well known a VFD will increase
system power demand when an electrical motor is running at or near
maximum speed. Consideration of
actual system design DRPL and SRPL
values and VFD and electrical-motor

safety factors may lead to reduced

overall VFD efficiency and, thus,
increased system power demand. An
increase in system power demand,
which is most critical during design
and near-design operational conditions, can be offset with an advanced
control system that allows realization of an optimal control strategy
for switchover from VFD to VFDbypass and from VFD-bypass to VFD
modes of operation. 1 This control
system can be employed for new
applications as well as for retrofits
to optimize electrical-motor power
demand. An electrical utility experiencing a shortage in (kilowatt)
capacity during peak-demand hours
could use it to reduce system cumulative power demand, rather than add
power-plant capacity.
At certain operational conditions,
the power demand of an electrical
motor running at variable speed
and frequency will be equal to the
power demand of the motor running
at constant speed and frequency
(i.e., line-voltage operation during
VFD bypass mode). The operational
point for switchover from VFD
bypass to VFD control is defined
by the c o nditio ns under w hic h
system power demand with VFD
control becomes lower than system
power demand at constant speed
and frequency. Switchover can be

EVALUATING POWER-DEMAND REDUCTION WITH VFD-CONTROLLED SYSTEMS

implemented locally, at the end-use

location, or remotely, from the site of
the electrical utility.

Conclusions
Takeaways from this analysis are:
t
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reduce power demand for customers
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critical operations at or near system
electrical peak-power conditions.

Reference
1) Burd, A.L., & Burd, G.S. (2012).
Optimized power demand control
system for electrical motors
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AD INDEX/READER SERVICE
CIRCLE NO.

155

PAGE NO.

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