Educational Settings

Alfred State College

Alfred, New York

Hydronic Heating, Boiler and Burner Controls

AT A GLANCE

Systems: Hydronic Heating, Boiler and Burner Controls

Equipment: Two (2) Weishaupt WM G60/2-A, ZM-NR high turndown (10:1) burners firing on natural gas

Solution: ECON-designed, custom steel mounting bracket to allow for seamless installation of two Weishaupt burners to the existing face of the LaMont boiler. The Weishaupt burners meet the substantially decreased loads required today, while also supporting additional reductions for years to come.

Results: Design supports overall goal of decentralized heating which is an essential element of the strategic, long-term campus energy plan.

THE CHALLENGE

Alfred State College, a 240-acre campus within the State University of New York (SUNY) system, is leading the way in reducing energy consumption. With a goal of a 30 percent reduction in the SUNY carbon footprint state-wide, academic campuses are evaluating and retrofitting existing systems. The Alfred State system currently uses a central heating plant with LaMont boilers. Moving towards a decentralized model, with the installation of individual heating sources in each building, the heating load on the existing LaMont boilers is decreasing each year. The existing burners can no longer turndown enough to meet this decrease load.

THE ECON SOLUTION

By supplying two new Weishaupt burners to Alfred State, the ECON design could meet the substantially decreased loads required at the central heating plant. Also, the new burners are sized for the anticipated reduction in load expected in the near future where even more load is shed from the central heating plant through use of additional individual heating sources.

University at Buffalo, Clinton Hall

Buffalo, New York

ECON solution: Hydronic Heating, Modbus Control System using StruxureWare.

AT A GLANCE

Systems: Hydronic Heating, Domestic Hot Water and Building Controls

Equipment: 

  • Hydronic packaged boilers and domestic heat exchangers
  • Expansion and Buffer tanks
  • Advanced Modbus Control System using StruxureWare with lead, lag, standby control sequence to maintain buffer tank set temperature.
  • High efficiency condensing boilers
  • Plate and frame heat exchangers

Solution: Pre-fabricated, single power source, fully tested boiler and heat exchangers skids, providing both domestic and hydronic heating within 0.25°F of set-point.

Results: Instantaneous demand, n+1 redundancy, increased efficiency

THE CHALLENGE

University at Buffalo, Clinton Hall is a 55,000-square foot residence hall originally constructed in the early 1970s. It primarily serves the housing needs for first-year students and is occupied around the clock. Typical of most college campuses, the University could not afford extended downtime for the demolition and installation of new equipment. Additionally, there were limited space and rigging constraints adding to the complexity of the project. There was also a need for new equipment to quickly connect to the existing building control system (BCS).

THE ECON SOLUTION

Recognizing the importance of limited downtime, ECON engineers designed a skidded solution that was installed and operational in two working days. This included connections for water, electric, and gas. By pre-engineering this custom-designed skid ECON provided accurate connection points to existing utilities. The use of precision engineering alleviated additional installation and set-up costs during commission. In order to better control building operations all points were wired and connected to a control panel making it ready for a quick connection to the existing building control system, and to minimize time consuming issues at the job site, the equipment package was pre-tested at the factory complete with the sequence of operation.

Pittsford Central School District

Pittsford, New York

Classroom settings

AT A GLANCE

Systems: Hydronic Heating, Domestic Water, Burner Controls

Equipment: Seven (7) Unilux hot water bent steel tube boilers with high turndown Weishaupt WM G20/2 burners

Solution: On-site construction and testing

Results: New boilers that received UL listing and ASME certification

THE CHALLENGE

One of the leading public school systems in New York State, Pittsford Central School District comprises 30-square miles that includes nine buildings serving over 6,000 students and 1,500 staff members. With aging equipment and limited boiler room access, installation of new certified boiler equipment required onsite installation and testing. This would only be possible by field erecting boilers with certified installers.

THE ECON SOLUTION

The ECON solution took into consideration the space restrictions throughout the access way into the school boiler rooms and used Unilux ZF-600W boilers that could be fully field-assembled and erected onsite. By working directly with the factory, ECON had all individual parts including boiler tubes, upper and lower drums, down comer and all boiler walls and exterior panels shipped directly to the site. This allowed for ease of installation because the boiler was brought in to the boiler room piece by piece. It was then erected by a certified Unilux team. By working with certified installers who could field erect the system, the Pittsford Central School District was able to achieve UL listing and ASME certification.

Northeast Area Central School

New York State

Educational Settings

AT A GLANCE

Systems: Hydronic, Domestic Hot Water

Equipment: Three (3) 87 Hp Hydronic packaged Boilers and Domestic Heat Exchangers

Solution: Pre-fabricated, fully tested Boiler and Heat Exchanger skids

Results: Instantaneous demand, n+1 redundancy, increased efficiency

THE CHALLENGE

Schools and colleges have several unique conditions and specific jurisdictional restraints that dictate the ability to innovative and to be creative in design. Large commanded early morning loads ensure the building is warm before the staff arrived. Equipment operation continues until the cleaning staff goes home late at night. With budgets being controlled by public motions an elected officials, equipment replacement and maintenance is more than challenging.

Over time, energy conservation and renewable energy demands changed the conceptual approach as to how replacement equipment was selected and how the controls operating those systems commanded boilers to maintain lower operating temperatures. New code compliance and the modular boiler design (as the new industry standard) was eagerly accepted in the early 1990’s with propane as the stand-by fuel. This revolutionized the industry allowing boilers to be designed to condense the flue gasses with lower reset water temperatures. Heat exchanger designs changed and boilers became virtually instantaneous as efficiencies rose to the higher than 90+% for full load operation. An entire new set of design challenges faced the industry as the systems changed from a water mass design to the application of the modular instantaneous cascading design.

THE ECON SOLUTION

Equipment short cycling, over-sizing, lack of knowledge on condensing opportunities, and interfacing with building controls play an extremely important part in the overall operation and efficiency of the terminal units. ECON tackles these challenges with our expertise in understanding the entire system design envelope and through Right-Sizing equipment. We know all the components in a building have to work together to communicate true load profile designs, all while being controlled from a single source. Our partnership with U&S Services Inc. allows our solutions to perform at maximum efficiency by working with the building controls rather than operating independently.

ECON provided a solution that was designed to simplify installation and minimize maintenance. By providing a fully pre-fabricated skidded solution, the contractor saw minimal risk of error during installation. Our unique, repeatable design for serving the domestic hot water needs kept the service water out of our boilers, while providing virtually instantaneous hot water at all capacities of demand. Our boiler and heat exchanger skids came pre-wired to join the building controls circuit in as few as 6 pin-style connectors. By understanding our role in designing easy to install solutions ECON made the tight project timeline possible for the contractor.