Harol Harold Esmailka, 85, a native Athabaskan who grew up in the Alaskan tribe’s traditional nomadic lifestyle, is a true entrepreneur, having started a variety of businesses over the years. His bush plane service made him an aviation legend in the back country, and he and his wife still operate a general store out of his Read more
US Boilers
Harol Harold Esmailka, 85, a native Athabaskan who grew up in the Alaskan tribe’s traditional nomadic lifestyle, is a true entrepreneur, having started a variety of businesses over the years. His bush plane service made him an aviation legend in the back country, and he and his wife still operate a general store out of his hilltop home overlooking the Yukon.
The home/store is a typical remote Alaskan trading post; butter, blankets, bullets and beer. Lots of beer. It’s the next best thing to Walmart, which is 240 air miles away; the same distance to the nearest plumbing supply house.
For technicians at Rocky’s Heating Service in Fairbanks, AK, this is often how a morning commute starts.
The store’s old boiler started leaking from a cracked section, so Harold started looking for a solution over the summer. In the meantime, he had an oil-fired Burnham V85 shipped to Ruby on a barge, to await its coming installation. This boiler is popular in AK because it’s available as a “breakdown” boiler that can be assembled on-site – a big plus for remote applications which often require flying, barging, or snowmobile transportation of boilers.
After speaking with supply houses in Fairbanks, Harold learned that Rocky’s Heating Service, out of Fairbanks, had completed a boiler installation in the village where his daughter lives. A few more phone calls for references, and Rocky’s was called for the job.
Rocky Pavey
The company was founded by Rocky and Catherine Pavey in 1994, and currently has 17 employees that serve most of the Alaskan interior. Robust hydronic systems comprise most of their work. Exceeding customer expectations is the ultimate goal of every Rocky’s technician.
One Tuesday morning in November, just as the Yukon started to freeze over, Pavey was able to make the flight out to Ruby himself.
It’s the logistics
Pavey packed 160 pounds of tools, pipe and parts to be flown out ahead of him on a dedicated freight flight. To conserve space, small diameter pipe was stashed inside larger pieces, and everything else was packed into one big tote. “You can’t get on a plane with MAPP gas, so I traded the torch for a press system and fittings,” he said.
The temperature dropped to -5°F the evening his plane touched down in Ruby. Not wanting to take Harold’s leaky boiler out of service overnight, he serviced three other boilers in town on Tuesday evening. Before going to bed, he added Fernox liquid cleaning agent to the four-zone hydronic system at the general store to circulate overnight.
Rocky Pavey about to touch down in Ruby, AK.
On Wednesday morning he drained the system. The fluid looked like mud due to the constant addition of untreated makeup water. After tearing out the old unit, he moved the circulator from the return piping to the supply side.
“Once you’re there with all the tools and material, installing a V8 is a cakewalk,” said Pavey. “We use them because it’s a tough boiler that’s quick and easy to install. When we’re in the remote villages, time is of the essence, and durability is a huge factor.”
At 85% efficient, the Burnham V8 is a cast iron boiler built to offer low cost of ownership and easy drop-in replacement for most systems. Seven sizes are available, from .75-2.6 GPH.
The village of Ruby, AK, on the banks of the Yukon River.
“The zone valves and wiring were a bit messy, but Harold wanted to replace as little as possible,” said Pavey. “When I was pulling materials back in Fairbanks, he told me that the expansion tank was in good shape. I learned otherwise when I got there.”
Luckily, there was an air freight shipment headed to Ruby on the morning he was to fly home.
When the new boiler was installed, the owner insisted on changing the piping as little as possible to trim costs.
While Pavey was piping the new boiler and running fresh soft-copper, his guys back in Fairbanks took an expansion tank to the airport. Wednesday night, Pavey filled the new boiler and left the old expansion tank in place. What he hoped to accomplish on Wednesday drifted into Thursday. He still had an expansion tank to replace and glycol to add to the system. As a result, he moved his flight home from Thursday morning to the afternoon.
Insurance policy
When the morning’s first flight arrived from Fairbanks, Pavey met it at the airfield to get the new tank. At that point, the countdown began. He had exactly two hours to swap tanks and add antifreeze and corrosion inhibitor to the system before his flight back to Fairbanks departed.
“Harold decided he wanted antifreeze in the system,” said Pavey. “Good idea, but is came at a cost. The air freight alone on 30 gallons of 50/50 propylene glycol was $307.”
Corrosion on the original boiler’s cracked sections.
But according to Pavey, both the antifreeze and the Fernox corrosion inhibitor are an insurance policy, a guard against the worst Mother Nature can throw at a heating system. Nights dropping below -50°F and wicked winds to accompany it make for long runtimes in a long heating season.
Just before Pavey headed to the airfield, Harold stopped him to ask if the system was actually running. He was concerned because his baseboard wasn’t gurgling, despite the building being warmer than ever. After explaining that the hydronic system was meant to be silent, and that the noise he’d grown accustomed to was a result of air in the pipes, Pavey caught his plane with minutes to spare.
Hard knock life
“Folks out here don’t have a lot to spend, but nobody in the country is more cognizant of their heating system than interior Alaskans,” explained Pavey. “Last year, fuel oil was $6.00 per gallon in the villages, and it doesn’t matter what the current barrel price is in the Gulf.”
Oil is barged to Ruby in the summer. When the town’s 75,000 gallons of storage is topped off, the price doesn’t change till the following year.
Harold was thrilled—and a bit surprised—that a professional heating outfit would make the trip to Ruby. With any luck, his position in the tribe will help spread the word of a job well done.
“Not long ago, we were only doing about one remote boiler installation each year,” said Pavey. “Since then, that number has crept up. The native community is tight knit, and the word has spread that we’re helping extend the life of systems while also lowering fuel bills. It’s an area where we expect to see growth in the years to come.
Because of its proximity to East Coast population centers, the Amish Country of Pennsylvania has become a wedding destination for out-of-towners. Lancaster County’s historic architecture can be seen all over the countryside, and it has garnered a lot of attention from wedding planners in New Jersey, New York and Philadelphia as “rustic” weddings have become Read more
Because of its proximity to East Coast population centers, the Amish Country of Pennsylvania has become a wedding destination for out-of-towners. Lancaster County’s historic architecture can be seen all over the countryside, and it has garnered a lot of attention from wedding planners in New Jersey, New York and Philadelphia as “rustic” weddings have become the latest craze.
White Chimneys, a historical farm in Gap, Pa., hosts weddings in an elegantly restored tobacco shed.
Gap, Pa., boasts as much old-time, Pennsylvania Dutch culture as anywhere in the state. Tobacco was the main cash crop for decades, and still is to some degree. Plenty of well-maintained tobacco “sheds” still remain, though the term “shed” doesn’t do the buildings any justice. Typically, they’re long, tall buildings with an intricate timber frame and clapboard siding that tilts out vertically to allow air to move through the structure as tobacco hangs to dry.
While beautiful, tobacco sheds pose bigger retrofit challenges than other barn styles found in the area. Outfitting one with a state-of-the-art HVAC system while maintaining historic integrity isn’t a job for just any contractor.
Ongoing improvements
Patriot Water Heater, in nearby Kirkwood, specializes in commercial water heater installations and hydronic heating. President Tom Soukup and Vice President Rich Zalepa founded the company nine years ago after moving to southeast PA from Long Island, NY. They forged their skills in New York City, and are no strangers to old buildings or unique applications.
(l to r) Tom Soukup, president of Patriot Water Heater, Rich Zalepa, vice president of Patriot Water Heater, and Dave Raabe, district manager at ROI Marketing.
“We consider ourselves ‘hydronic artisans’,” said Soukup. “We pair old-school workmanship and ingenuity with modern technology to provide high-efficiency solutions for any building.” They’re also known for never backing down from a challenge.
Soukup met the owner of a large horse farm in 2009, as they were entertaining the idea of turning their huge tobacco shed into a wedding venue. He was hired to help to turn the shed into what is now known as Weddings at White Chimneys. As the years passed, the barn was refined and the cost to host a wedding steadily increased. But without an HVAC system, it was only useable for four or five months of the year. In 2015, the owner approached Soukup and Zalepa about changing that.
“It always starts with the math,” said Soukup. “We did a full heat loss calculation to determine the heating capacity required for the building. They had insulated the building envelope a few years ago when they installed AC, so it wasn’t as bad as you’d think, but we still needed more than 100,000 BTUH.”
After they had the numbers, the real fun began.
Unique building, unique design
The barn’s open 3,700 square-foot floorplan and its vaulted ceiling presented a challenge in respect to heating the space evenly. So the plan was to use a fabric ductwork system connected to two five-ton Trane air handlers. In addition to supplying AC via the existing condensing units, the air handlers each include a hydronic coil with heat supplied by a US Boiler X-C condensing boiler.
To supply all heat to the 100+ year-old tobacco shed, Patriot water heater installed a 120 MBH US Boiler X-C condensing boiler.
“Economy was key here, both on upfront cost and operating cost,” explained Soukup. “Both the fabric ducts and the X-C boiler were chosen because they offer a lot of bang for buck. The boiler’s controls also provide a ton of flexibility without sacrificing simplicity.”
The value-priced, stainless steel X-C features the same Sage 2.2 controls found on Alpine and K2 boilers. It’s available in five sizes from 80 to 180 MBH and provides up to 95% AFUE.
Two, 32-foot-lengths of fabric ductwork are installed on a simple hanger system high on the left side of the barn. The fabric duct collapses when the air handlers aren’t running, and inflates to provide uniform, low velocity air supply when in operation. This keeps heating or cooling temperatures consistent from the front to the back of the barn without any noticeable draft. But Soukup took extra precaution to be sure that warm air wasn’t stratifying up toward the ceiling. Several ceiling fans are installed on mid-height beams throughout the building to ensure consistent temps from floor to ceiling.
Like the X-C boiler, the use of fabric DuctSox provides a comfortable, quiet solution at a bargain price.
Patriot Water Heater also had to consider one more aspect that separated the White Chimney’s project from nearly every other commercial or residential application they tackle on a regular basis. Despite being ready for year-round use, the barn often goes unused for two or three weeks at a time.
Two-stage, cold start
“If there isn’t an event planned for an extended period of time, the owner understandably doesn’t want to heat the facility during downtime,” said Soukup. “So we needed a way to bring the temperature up quickly without having a huge input at standby. The simplicity of US Boiler’s Sage 2.2 controls allowed us to do this.”
The Patriot Water Heater uses ecobee web-enabled thermostats to connect system components when both heating and cooling are integrated.
Soukup and Zalepa created a two-stage system while utilizing only one zone of heat. Stage one operates as normal, supplying as low a water temperature as possible to the hydronic coils based on outdoor reset. This is typically between 120°F and 145°F. Stage two runs off the boiler’s DHW contacts, and bypasses the ODR to supply 180°F water to the coils.
This arrangement brings the building up to temperature rapidly, while providing high efficiency through lowered water temperatures for the other 95% of the time. According to Soukup, he hasn’t found an application where the flexibility of the Sage 2.2 boiler controls has left him without options.
Two, five-ton Trane air handlers provide heat to the huge wedding venue through the use of hot water coils.
“These Sage controls are one of the main reasons we switched to US Boiler products about a year ago,” explained Soukup. “Since then, we’ve installed about 25 Alpines and K2 boilers. This is the first X-C we’ve put in, and it will be one of many.”
Rich Zalepa, VP of Patriot Water Heater, adjusts ODR setpoints on the X-C condensing boiler.
Outstanding technical support, both from US Boiler and rep firm ROI Marketing, is the other big reason they stopped using other brands. Dave Raabe, district manager at ROI Marketing, was a big help during the initial design phase at White Chimneys. His input ultimately helped Patriot Water Heater forge a lasting relationship with the owner at the wedding venue.
Continuing work
“The owner at White Chimneys is more than pleased with the performance of the system,” said Soukup. “It’s comfortable, efficient, and just as importantly, it’s quiet.”
At the moment, there’s glycol in the hydronic system for those periods of cold-weather shut down. But Patriot Water Heater is planning to install a radiant system under the barn floor next summer, along with another X-C boiler. That will allow the barn to remain at 50°F between events, and limit the amount of time the heating system needs to fire on stage two.
The mechanical space
“Patriot Water Heater has always done a great variety of work in Pennsylvania, New Jersey and New York, but I have to admit, this is the first time we’ve ever worked on a barn,” said Soukup. “If the rustic wedding trend continues, it might not be the last.”
For more information on Patriot Water Heater, please visit patriotwaterheater.com or check them out on Facebook at facebook.com/PatriotH2OHeaterCo.
With tens of thousands of registered mechanical firms around the country, naming a new company isn’t easy. Each approach can have advantages and drawbacks. For example, giving it the founder’s name might avoid availability issues, but it could hurt when it comes time to sell the company years down the road. Acronyms can be great Read more
With tens of thousands of registered mechanical firms around the country, naming a new company isn’t easy. Each approach can have advantages and drawbacks. For example, giving it the founder’s name might avoid availability issues, but it could hurt when it comes time to sell the company years down the road. Acronyms can be great, but confusing if not done carefully.
Sometimes, the best names are a bit off-the-wall. But a unique, memorable name isn’t a ticket for a smooth ride into a lucrative market, as Keefer Rader learned after starting Outlaw Mechanical, LLC., in 2008.
Keefer and Dorian Rader co-own Outlaw Mechanical. Official “outlaw dog,” Kayla, oversees daily operation.
“With a name like Outlaw, the first year was pretty tough,” said Rader, whose four-man shop in Sandia Park, NM installs and services all types of residential HVAC systems. The company’s name and logo (a skull and cross wrenches, wearing a cowboy hat and bandana) definitely has a lot of “cool factor,” yet was disconcerting for some customers at first. However, the unusual name resonates with Rader.
“We’re industry ‘outlaws’ in our area because I don’t pay my technicians based on commission,” he explained. “That approach is pretty standard here in the Southwest, but it doesn’t align with our company culture. It’s the only way we can ensure our customers receive the highest quality and most honest service possible.”
Keefer Rader, of Outlaw Mechanical, prepares to fire a new Alpine boiler.
A self-admitted perfectionist, Rader has intentionally kept the company small. Any more than four employees, he says, makes it tough to maintain his high standards. “We install only the best equipment, period. If you want cheap, look elsewhere.”
Climate of extremes
As the crow flies, Sandia Park is 15 miles East of Albuquerque, with a slender mountain range between. Like many high-desert regions, both heating and cooling seasons can be intense. Outlaw Mechanical uses a -38°F outdoor design temperature for heating, and cooling systems are designed to handle long, dry days above 100°F. New Mexico is one of the few places where a technician may work on a boiler and an evaporative cooler — sometimes called a swamp cooler — in the same day.
“When most people think of New Mexico, mountains don’t come to mind,” said Rader. “But we have boilers installed from 4,000 feet above sea level to 9,000. They’re almost all Burnham Alpines, which has been a phenomenal product. My competition uses other brands, and all I ever hear them talk about is electrical problems. Meanwhile, we’ve had no issues at all.”
Outlaw Mechanical LLC., in Sandia Park, NM, used a Burnham Alpine 210 to increase comfort, but fuel expenses, and drastically reduce noise in a local church.
When the Alpine’s wireless outdoor reset control was introduced, Outlaw Mechanical probably appreciated it as much as any installer in the country. Southwestern homes are notorious for tight mechanical spaces located in the middle of the building, and with the “adobe” style being so prevalent, many homes don’t have an attic through which to pull a wire.
“Outdoor reset is critical in this area,” said Rader. “As is adjustment; I can’t tell you how many times I’ve walked into a home that’s 90°F inside, in March. With our big temperature swings from night to day, it’s easy to overshoot the slab on a radiant system if the outdoor reset isn’t set properly.”
Custom homes with in-floor heat make up a large portion of the company’s work. On occasion, they’ll take on a project that strays from their residential focus, but because the Alpine’s size range is from 80 to 800 MBH, it’s flexible enough for almost any application.
Hydronic conversion
A nearby, 5,000-square-foot church was plagued by a 40-year-old furnace. The obnoxiously-loud unit was installed adjacent to the auditorium, where worship services are held. Hours before church on Sunday, congregation members would fire the furnace, bringing the building up to nearly 80°F, then shut it off for the duration of the service so it wasn’t a distraction. In August, they decided to make a change for the coming winter.
Initially, the church planned to install a new furnace, but the old ductwork left cold spots in various rooms. After looking at a number of options, Rader proposed a plan to install hydronic baseboard as a quiet, comfortable, efficient alternative.
A month later, the facility had a new, seven-zone heating system, as well as a stub-out for the future addition of domestic hot water. From the new Alpine 210 condensing boiler, Rahau PEX was pulled through the crawlspace to feed 430 linear feet of fin-tube baseboard. Each zone was individually served by a three-speed Taco 0015.
Fits the room, fits the budget
According to Rader, there were two challenges: Installing baseboard in an existing building while limiting disturbance, and packing all near-boiler piping into a 48” x 48” closet.
For the first obstacle, Outlaw Technicians took their time cutting through walls to limit the damage to the structure. Moving slowly and carefully while assessing each wall penetration was key. As for the mechanical room, laying the piping design out before starting a torch ensured there would be plenty of room for all components.
The Alpine boiler was placed on a custom built equipment stand with all secondary piping overhead. The row of circulators wraps around a corner, with a Taco 4900 air separator installed on the supply.
“I don’t want my name on a messy or inferior installation,” said Rader. “So when the baseboard work drug out because we were being so cautious about cutting holes, we made it fit the budget by donating some labor to the church.”
Church members have been thrilled with the comfort improvements. There are no cold rooms anymore, and most importantly, the heat can be on during a church service without the roar of an antique furnace in the background.
“The old furnace was 50% efficient, and the Alpine is 95%,” said Rader. “They love the system already. Wait until they see the fuel savings this winter.”
“We’re putting the band back together.” A go-to phrase from the 1980 classic comedy, The Blues Brothers, that’s what it felt like last month in Hershey, Pa. The niche show dedicated to the oil and energy service professionals had its reunion feel back, and the 61st OESP Annual Trade Show & Convention featured its cast Read more
“We’re putting the band back together.” A go-to phrase from the 1980 classic comedy, The Blues Brothers, that’s what it felt like last month in Hershey, Pa. The niche show dedicated to the oil and energy service professionals had its reunion feel back, and the 61st OESP Annual Trade Show & Convention featured its cast of characters in attendance.
In truth, last year’s two-part OESP Roadshow, a noble effort, which tried to bring the show closer to contractors, lacked solid attendance numbers. Yet, bringing it back to Hershey, its sweet spot—pun intended—you could feel the energy, and all exhibitors and attendees were satiated.
Dave Sweet (r), product manager, Taco, talks to an attendee about Zone Sentry zone valves.
OESP, the association dedicated to the Oil & Energy Service Professional, held consistent on its mission of education with a diverse program, including two of NORA’s new courses on airflow and hydronics, as well as a full trade show. “OESP changed its name a few years ago to reflect an evolution in its industry and its membership. Many conventional fuel oil dealers are adding propane to their offerings, as well as HVAC, plumbing, electrical, etc.,” said Al Breda, president.
Mike LaVigne (l), engineer, Energy Kinetics, live fires a 90+ Resolute boiler for an attendee.
“Since 1999, the oil heating industry has changed dramatically, and it has been tough for many companies, and thus our members,” said Judy Garber, OESP executive director—her last as acting director. “I’ve watched those who have accepted the challenge and moved toward diversification. In 1999, oil companies delivered to and serviced only oil heated homes and businesses. Today, they install solar, bathrooms, propane and gas appliances, and they quote new efficient oil-fired boilers and gas appliances. Today’s progressive companies control their routes with GPS, customers receive and pay their invoices electronically, often times right on the spot with handheld devices,” said Garber.
Dave Hansen, product marketing manager, U.S. boiler Co., talks with the Hub’s Eric Aune about the K2 boiler system’s Fast Pipe, which is designed to be an affordable primary/secondary piping solution that can help all contractors.
Charitable Events
This year’s OESP Convention featured the The Dave Nelsen Scholarship Golf Tournament, which has raised more than $250,000 in awards—since 1999—has been presented to students interested in pursuing careers in the energy-service industry. The scholarship recipients are Roger Bruso, Jeffrey Comitz, Thomas Daros, Jr., Erik Graff, Michael Boylston, and Garth Reish.
Oil Heat Cares’ Care to Ride raised funds for oil-heating equipment replacements for people who are struggling to heat their homes. The following people were recognized for their commitment to Oil Heat Cares:
• Oil Heat Cares Cup: Judy Garber and Dan Holohan
• Top Fundraising Team: Team Connecticut
• Top Fundraiser Motorcycle Division: Ralph Adams
• Top Fundraiser Bicycle Division: Roger Marran
• Top Fundraiser Walking Division: Dan and Marianne Holohan
Awards Banquet
The Awards Banquet on Tuesday, May 19 was a special night, a night which saw OESP honor Garber for her outstanding contributions to the industry. Garber received the Lifetime Achievement Award alongside her family and friends. At a loss for words, she had said that she is rarely surprised, but that night was an exception, and the outpouring of appreciation overwhelmed her.
Judy Garber, overcome with emotion, shares the moment with her father.
During the awards banquet, OESP also recognized Dan Holohan for his support to the association, establishing the Dan Holohan Scholarship, a scholarship set up in his name identifying the top instructors in the industry. Those teaching future technicians will be able to either purchase materials to enhance their training or attend a class or program that enriched their skills as an instructor.
Dan Holohan, after receiving the award dedicated in his name, does what Dan does best, connects with his audience.
Holohan, who has announced his retirement, has said, “This is my final year of doing seminars. My last will be at the AHR show in Orlando next January.”
OESP & AREE Partner
OESP and the Atlantic Region Energy Expo (AREE) recently announced they will host a joint trade show and convention next year — May 22-26, 2016 — at the Foxwoods Casino Resort, Ledyard, CT.
Eric DeGesero, executive vice president, Fuel Merchants Association of New Jersey, a prime sponsor that provides show management services for AREE commented, “This joint venture is a logical step in a consolidating industry.”
“Our goal is to continue to provide the forum that brings all segments of the petroleum marketing industry together to network and learn. Not only will we be continuing these efforts on behalf of motor fuel and heating fuel distributors but adding the technical educational component that OESP does so well,” DeGesero said.
According to OESP’s Garber, something needed to happen; there are too many shows with too few people attending them.
“We need to build an outstanding product that attendees know they need to attend. The oil industry is shrinking but it sure isn’t going away. OESP is evolving but it will take time to attract those in other energy businesses. Our focus is on service and installation, and by partnering with AREE, we are stronger and we can together be a very strong show in the Northeast when it comes to oil and energy.
“The joint show provides each of us the ability to sponsor an industry-wide convention and trade show that will provide a wider audience. It will also provide OESP greater exposure to our industry as we will now be able to showcase our extensive technical education programming to owners and managers,” said Garber.
The new Burnham K2 condensing boiler was designed based on feedback from field professionals who were asking for an easier boiler to service and install. In addition, the combination of high efficiency, performance and high value make the K2 ideal for households that might otherwise opt for a traditional boiler. At up to 94 percent Read more
The new Burnham K2 condensing boiler was designed based on feedback from field professionals who were asking for an easier boiler to service and install. In addition, the combination of high efficiency, performance and high value make the K2 ideal for households that might otherwise opt for a traditional boiler.
At up to 94 percent AFUE, this ENERGY STAR rated boiler uses a proven stainless steel heat exchanger and cutting edge Sage 2.1 Control System with factory pre-sets to speed installation.Touch screen diagnostic display and free five-year parts & limited labor warranty offer additional benefit.
The K2 is available in five sizes ranging from 80 to 180 MBH, and offers features such as 5:1 turndown and a “cold burner door” that’s safe to touch even while firing. The boiler’s simplified design includes a hinged inner door that isolates electronics and controls from combustion and waterside components, making for fast, clutter-free service access.
A pre-installed, high capacity boiler loop circulator is included, as is an innovative split-voltage junction box, enabling simple, error-free wiring connections. Venting the K2 is simple as well, regardless of whether one pipe, two pipe, horizontal or vertical configurations are needed.
