Radiant Cooling

Hydronic systems outperform VRF, study finds

In a study commissioned by Xylem Inc. that evaluated HVAC systems in a number of South Carolina school buildings, hydronic systems outperformed all other systems, including VRF, in terms of lower energy use, cost and life expectancy, by as much as 24%.

“With HVAC systems dictating a substantial amount of the overall energy use of commercial buildings, the results shed light on the importance of evaluating varying system-to-system costs before installation,” said Kyle DelPiano, Business Development Director, CBS Market, Xylem. “More than ever, energy-efficient practices are driving the construction industry toward more sustainable solutions, and this study proves long-term cost savings that can’t be overlooked when making the choice between hydronic and VRF systems.”

To compare and contrast HVAC systems according to their 30-year life-cycle cost analysis (LCCA), the Xylem study analyzed seven elementary and middle schools located in South Carolina Climate Zone 3A, a humid, warm climate. The cost analysis included upfront installed cost, replacement cost allocations and ongoing energy and maintenance cost of the following system types:

• Variable refrigerant flow heat pumps (VRF)
• Water source heat pumps (WSHP)
• Ground source heat pumps (GSHP)
• Direct expansion rooftop units (DX RTU)
• Water cooled chillers (WCC)
• Air-Cooled Chillers (ACC)

The findings of the study revealed that the schools with WSHP, GSHP and WCC systems displayed energy use levels that were 30%, 41% and 25% better than the national median for elementary and middle schools, respectively. The replacement cost allocation also acknowledged that the tested hydronic systems operate effectively for approximately 25 years, as opposed to the 15-year replacement estimation for VRF systems.

The tested VRF systems required replacement a decade earlier because of their tendency to work harder during heating cycles, bringing proof of long-term cost savings to the forefront of the conversation surrounding sustainability and hydronic HVAC system efficiency.

Replacement allocations had an impact on the life-cycle cost analysis (see yellow bars) and drastically reduced the cost effectiveness of equipment with 15-year life expectancies.

Considerable benefits of the hydronic HVAC systems included lower energy usage intensity and cost, wider range of maintenance flexibility and longer life expectancy.

The full research study can be found here: https://bit.ly/35AtpXb. For more information about Xylem, visit www.xylem.com.

 

For the past 11 years, my job as a technical trainer has taken me from Alaska to Cuba, with many stops in between—I have been to all 50 states. Transitioning from a hands-on plumber to a talking head, standing in the front of the room addressing thirsty-for-knowledge contractors, took some getting used to.

No doubt the travel part of a “traveling trainer” job is the most challenging.  Hours spent squeezed inside an aluminum sausage, aka big, old jet-airliner, can be frustrating. I do love the views and amazing sunset and sunrises I have seen.  Lightning show, massive clouds are incredible, but they never look the same on the phone camera. For the most part the airline folks have been helpful and accommodating.

When they see the miles you rack up as a business traveler, they will almost always accommodate your request. Approaching them without a chip on your shoulder helps the outcome. Maybe it’s me, but it seems like a lot more delays and cancelations lately, busy times in the air travel business. So, I usually plan for some shuffling and exercise some chill skills. But I digress.

Once at the location, the fun part begins for me. I enjoy sharing what I have learned and listening to stories from attendees. For sure, my favorite parts of the job are the shop and jobsite visits. I learn from seeing how the new products and technology are actually being blended together on actual jobs. Browsing through the back rooms of the wholesaler and rep buildings can provide some good intel.

I try to balance my training between product pitch and theory, applications, tips and tricks. It is important that the training sponsors advertise and promote the training accurately. If the training is intended to be all product and sales, that needs to be clear, so the folks attending know what to expect. Technical guys and gals prefer technical topics, from my experience.

I try to engage the group as much as possible, learn their skill level and expected outcome. Training for me is a give and take experience, as nobody knows it all. Except perhaps my wife. (Shhhh!) Generally, the room is a mix of expertise levels, so try to include info for everyone to leave with. Know your audience!

The dynamics of a room vary depending on the group. If you have a roomful of competitors, the questions do not flow so easily. Training at shops, reps and wholesalers always result in more interaction.

During the lunch break, spring for some food for the group, even if it is good pizza. Shop for the local brand favorite.

I’ve found a 4-hour maximum for tech heavy topics is a good lid for an event. It’s tough to keep a blue-collar person down as they need to keep moving. Their backs and knees make sitting for a long time challenging, too.

I always want to leave the attendees with a nice hard copy of the material we covered. The Caleffi Idronics are perfect handouts: They are a reference, both as a hard copy and online version. Also, it’s always nice to see the group taking notes in the margins.

Back at the office—in-house—I help produce the Coffee with Caleffi series, a webinar that cover important topics in the plumbing and hydronics industry.

If we haven’t met or shared a gab session together, I hope to do so soon. I’ll keep in communication with the Mechanical Hub community about dates and times for upcoming seminars, and webinars!

Bob ‘Hot Rod’ Rohr is director of training and education at Caleffi.

More speakers, more topics, plus a sold-out trade show

The Canadian Hydronics Conference (CHC2019) opens in Ottawa, Canada in just four weeks (September 24-25). The two-day conference includes a sold-out trade show and is attracting contractors, wholesalers and engineers from across Canada. The Conference is presented for the industry by the Canadian Hydronics Council (CHC), a council of the Canadian Institute of Plumbing & Heating. CHC has be representing Canada’s hydronics (modern hot water heating) industry for more than 40 years.

“With 20 presenters from across Canada and the U.S. it’s an exciting program”, stated Conference Co-Chair Mike Wills of Wolseley Canada. “Whether you are a seasoned pro or newer to the industry, CHC2019 will give you the technical training, business insights, product information and industry contacts you need to succeed”.

“It’s going to be an incredible opportunity to meet North America’s leading hydronics industry leaders”, added Conference Co-Chair Dave Harrison of Jess-Don Dunford Limited. “It’s also a fantastic way to meet other industry members from across Canada and share ideas”.

CIPH Chairman of the Board Andrew Dyck of Barclay Sales Ltd. along with the Canadian Hydronics Council Chairman Dave Hughes will attend the conference and present the 2019 Canadian Hydronics Council Award of Merit. The award recognizes an individual for their significant contributions over a lifetime to the Canadian hydronics industry; it is the hydronics industry’s highest honor. The presentation will take place at 1:30 pm on Wednesday, September 25.

For complete details about the Canadian Hydronics Conference and registration information, visit www.ciph.com/CHC2019 or email info@ciph.com.

Previous CHC Award of Merit Recipients

 2018

Barry Cunningham, General Manager, Triangle Supply Ltd. (a division of Bartle & Gibson Co. Ltd.)

Kenneth Webster, formerly Director, Sales & Marketing, Viessmann Manufacturing Company Inc. (retired)

2017

Richard Peck, Vice President, Slant/Fin Ltd.

2014

Roy Collver, Contributing Editor – Hydronics, Plumbing & HVAC Magazine

Harald Prell, President, Viessmann Manufacturing Company Inc. (Canada)

2013

John Goshulak, Vice President, Sales and Marketing, Weil-McLain Canada Sales Inc.

 

Recently, the Mechanical Hub team took part in a two-phase, two-state trip to visit Viega’s North American manufacturing in McPherson, Kansas, and toured the brand new HQ and Seminar Center in Broomfield, Colo. Impressive is the first thing that comes to mind when describing both facilities.

The McPherson manufacturing facility exudes the company’s philosophy of both progress and vision for the future. “We are constantly looking past the immediate future and into the distant future,” Eric Wicker, director, manufacturing, Viega.

This summer, Viega completed a two-year building program in McPherson that included: a 90,000-sq. ft. expansion of a manufacturing plant, completed in Dec. 2017; a new 205,000-sq.-ft. manufacturing plant, completed in June; and a new 25,000-sq.-ft. tool shop and apprentice building, completed in July. And, the company is currently building a 55,000-sq.-ft. logistics expansion—a high-bay storage and retrieval area for inventory.

Mimicking some of the processes from its global HQ in Germany, robotics and machining take center stage throughout the meticulous McPherson plant. Fear not, all of this new-fangled technology is not taking jobs away, rather increasing them. Currently at approximately 300 employees, the company hopes to hit the 500 mark by years ’23-’24.

McPherson is where Viega produces its PureFlow line of PEX product, as well as select fittings from the ProPress Copper and 80,000 sq. ft. dedicated to its MegaPress product lines. McPherson is also home to Viega’s master distribution center for North America.

Continued expansion is a testament to the company’s progressive philosophy. For instance, the company has dedicated 270,000 sq. ft. to the copper fitting production. “The goal is to be producing the majority of copper fittings sold in the U.S. right here in the states,” says Wicker.

 

 

The state-of-the-art distribution center incorporates the latest technology and automation, as well as an upgraded warehouse management system that provides faster product turnaround. With additional metals products being manufactured in McPherson, a larger distribution center for both metals and PEX products was necessary.

Although media wasn’t allowed to shoot photography inside the plants—understandably—the tour started in the 36,000-sq.-ft. Plastic Injection Molding area which exemplified the company’s high investment in tooling. Twenty machines produce approximately seven million fittings per month. This particular building was well lit and comfortable, due, in part, by the implementation of its own radiant heating and cooling technology.

Quality is never understated at Viega; we strolled through the Quality Assurance Lab where dedicated staff monitor product and equipment through a series of rigorous testing.

Next, we toured the 200,000-sq.-ft. Extrusion Area where the plastic piping is made. Once made and exported from Georgia, Viega now produces its own resin—which is transformed into pellets—onsite. The rejected pellets are not repurposed, yet recycled and sold.

There is a Special Extrusion Area where plastic metal plastic tubing extrusion is performed. The only company in America making this, the plastic piping is integrated with aluminum so it can better hold its shape rather than returning back to its original form. (Nearby is a 40,000-sq.-ft. dedicated machine shop.)

We then toured the 270,000 sq. ft. of ProPress copper fittings production area and 80,000 sq. ft. of the MegaPress/Metals production area. Strategically, it makes sense for Viega to start producing here in the states. With press technology introduced here in 1999, education and awareness of the process and technology have helped contractors nationwide run a more efficient business. Viega system solutions are designed to work together in plumbing, heating, cooling and pipe joining applications, making the contractor’s work fast, easy and safe.

The following day we were flown to Denver to tour the recently opened Viega North American headquarters and Seminar Center in Broomfield, Colo. The 55,000-sq.-ft. headquarters resembles a pipe fitting, and its interior is the real testament to Viega innovation. I can’t express enough how beautiful these two buildings are, and, of course, amid the breathtaking backdrop of the Rocky Mountains. The HQ building opened in January and the first official training took place April 8, and weekly training is booking fast. “Viega is absolutely committed to its customers and their success in the field,” says Bo DeAngelo, manager, technical training at the center.

Yet, I am always interested: when a new facility is built, does it incorporate its own products? While the cross-laminated timber beams are imported from Austria, the exposed ceilings give employees and visitors a clear view of the many uses of Viega’s innovative technology.

Potable water is carried through copper pipes connected with ProPress fittings. The carbon steel fire sprinkler system is joined with MegaPress fittings. Radiant heating and cooling keeps the building comfortable, while a snowmelt system keeps the courtyard free of ice and snow. Manifolds ensure the systems operate smoothly and efficiently. The restrooms feature wall-hung bowls and no exposed tanks, thanks to in-wall carrier systems and Visign style flush plates.

The new 23,000-sq.-ft. Broomfield Seminar Center next door supplements Viega’s Nashua, New Hampshire Seminar Center, which has trained thousands of people since opening in 2006. The new center is an innovative training experience and is equipped with four classrooms, two hands-on labs, and interactive displays throughout, which allows attendees to see, touch and experience Viega products. “Demand for training has been increasing steadily. This facility will allow us to continue to provide and expand on the training that our industry deserves,” says CEO Dave Garlow.

Viega experts lead single- and multi-day classes in everything from radiant system design and fire protection to hydronics and pathogen prevention. Despite being open only since April, it is on track to host more than 2,100 students this year, says DeAngelo.

I walked away very impressed, telling DeAngelo I—and I’m sure the clients that visit—can’t help but feel energized the minute I walk in this facility. Shaking his head in agreement, “That’s what Dave Garlow tells me every day he walks in here,” responded DeAngelo.

Make no mistake, there is a lot of money, time and resources invested in Viega North America. But it’s a huge testament to the dedication the company believes is its biggest investment: its customers and its employees.