SVL and Flow had a 45-minute live streamed session featuring an engaging conversation with Sean Jarvie, a leading expert from Flow, where we delved into the transformative potential of CO2 heat pumps. We explored their impressive energy efficiency, delivering year-round comfort and quiet operation while significantly reducing the environmental impact. He closed by bringing the future of climate control to life, Sean presented a live demonstration of the Answr Heat Pump unit.

How Does a Flow Heat Pump Work?

Flow heat pumps operate on the principle of heat transfer. They act like a reverse air conditioner, absorbing heat from a cool source (air or ground) and transferring it to your home for warmth. In the summer, the process reverses, extracting heat from your home and releasing it outdoors. Unlike traditional systems that rely on burning fossil fuels to generate heat, flow heat pumps utilize electricity to move existing thermal energy.

There are two main types of flow heat pumps:

• Air-source heat pumps: These systems extract and release heat from the outside air. They’re a good choice for moderate climates.
• Ground-source heat pumps (geothermal): These systems utilize the constant temperature of the earth below the frost line as a heat source or sink. They offer higher efficiency but require more upfront investment for installation.

Benefits of Flow Heat Pumps:

Energy Efficiency: Compared to traditional systems, flow heat pumps can significantly lower your energy consumption. By transferring existing heat instead of generating it, they require less electricity to maintain your desired temperature. This translates to lower energy bills and a reduced carbon footprint.

Year-Round Comfort: Flow heat pumps offer both heating and cooling capabilities in one system, eliminating the need for separate furnace and air conditioning units. They provide consistent and comfortable temperatures all year long.

Quiet Operation: Flow heat pumps generally operate much quieter than traditional systems, creating a more peaceful living environment.

Environmental Benefits: By relying on electricity and utilizing renewable energy sources like solar panels, flow heat pumps can significantly reduce your home’s reliance on fossil fuels and greenhouse gas emissions.

Long Lifespan: With proper maintenance, flow heat pumps can have a lifespan of up to 15-20 years, potentially exceeding traditional heating and cooling systems.

Government Incentives: In many regions, government incentives are available to encourage homeowners to switch to energy-efficient technologies like flow heat pumps. These incentives can help offset the initial cost of installation.

Things to Consider Before Installing a Flow Heat Pump:

Climate: Flow heat pumps perform best in moderate climates. While air-source models can operate in colder areas, their efficiency can decrease significantly. Ground-source systems offer more consistent efficiency but require a higher upfront investment.

Initial Cost: The installation of a flow heat pump system can be more expensive than traditional systems. However, the long-term savings on energy bills and potential government incentives can make it a worthwhile investment.

Home Size and Insulation: Flow heat pumps are most effective in well-insulated homes. They may not be suitable for very large houses, as their capacity might be insufficient.

Maintenance: While generally low-maintenance, regular cleaning and professional service are crucial to maintain efficiency and lifespan.

Availability of Qualified Installers: Ensure you find a qualified and experienced HVAC contractor familiar with flow heat pump technology for proper installation and maintenance.

Conclusion

Flow heat pumps offer a compelling solution for those seeking an energy-efficient and environmentally friendly way to achieve year-round comfort. While some upfront costs and considerations exist, the long-term benefits in terms of energy savings, environmental impact, and comfort make flow heat pumps an attractive option. If you’re looking for a sustainable and innovative way to heat and cool, consider exploring Flow Heat Pumps.

Embrace the future of HVAC&R. Discover how Flow Heat Pumps can ensure long-lasting comfort and sustainability.

Our latest Coffee Break Webinar, a 45-minute session titled “Reducing Emissions & Operating Costs by Unlocking the Power of Clean Steam” featured a conversation with Joe Singerling from Fulton Boilers. We discussed the critical role of steam quality and explored Fulton’s clean steam systems, their diverse applications, and the factors influencing their efficiency.

What is Clean Steam?

Clean steam is steam with low moisture content and minimal contaminants. Traditional steam, also known as “plant steam,” is sufficient for many applications where the steam doesn’t directly contact the product. However, in industries like food processing and pharmaceuticals, stricter standards are necessary. Clean steam offers several advantages:

• Reduced Risk of Contamination: Lower moisture content translates to less carryover of impurities and minerals that could contaminate the product.
• Improved Process Control: Consistent steam quality ensures predictable and repeatable results in processes.

Levels of Clean Steam

The requirements for clean steam vary depending on the industry and application. Here’s a breakdown of the different levels of clean steam discussed in the seminar:

• Plant Steam: This is the most basic level of steam quality. It is used in applications where steam does not come into direct contact with the product, such as heating buildings or powering turbines.
• Culinary Steam: Used in food processing applications, culinary steam requires filtration to remove particles larger than 2 microns. It may also involve the use of FDA-approved chemicals for sanitation.
• Clean Steam (Generic): This is a general term for steam that is free of chemicals. It typically uses softened water, reverse osmosis, or deionized water to achieve minimal contaminants. Clean steam systems may utilize a dedicated boiler or a secondary steam generator.
• Pure Steam: This is the highest level of clean steam, with virtually no impurities. It is used in critical applications within the pharmaceutical industry. Pure steam systems require stringent standards, including 316 stainless steel piping and all-welded connections to minimize contamination risks.

Key Factors for Clean Steam Systems

Several factors influence the effectiveness of clean steam systems:

• Moisture Content: As mentioned earlier, lower moisture content is essential for minimizing contaminant carryover.
• Boiler Pressure: operating at Lower steam  pressures can generate larger steam bubbles, which can increase moisture content.
• Water Treatment: Proper water treatment is crucial to prevent scale buildup in the boiler and pipes, which can not only reduce efficiency but also lead to contamination.
• System Design: Careful consideration needs to be given to system design aspects like appropriate pipe sizing and maintaining proper water levels in the boiler to ensure optimal clean steam generation.

Challenges of Clean Steam Systems

While clean steam offers significant benefits, there are also challenges to consider:

• Cost: Higher levels of clean steam require more expensive materials and components for boilers, piping, and filtration systems.
• Boiler Life: Running a boiler without the use of certain chemicals can potentially reduce its lifespan. Implementing proper boiler maintenance practices becomes even more critical in clean steam systems.
• Large Instantaneous Loads: Sudden spikes in steam demand can overwhelm the boiler’s capacity, potentially compromising steam quality. Proper system design and boiler sizing are essential to handle anticipated fluctuations in demand.

Fulton Boilers and Clean Steam Solutions

Fulton Boilers has extensive experience in designing and manufacturing boilers for various clean steam applications. The seminar provided a deeper understanding of the intricacies of clean steam systems and the various factors that influence their performance. By carefully assessing these factors and selecting the appropriate equipment and water treatment solutions, facilities can ensure they achieve the desired level of clean steam quality for their specific needs.

In Conclusion

Clean steam systems play a vital role in various applications, ensuring product quality and process consistency. Understanding the different levels of clean steam, the factors that influence their effectiveness, and the challenges involved is crucial for selecting the right system for your application. If you’re considering implementing a clean steam system, consulting with a reputable boiler manufacturer like Fulton Boilers can be extremely beneficial. Their expertise can help you navigate the various considerations and design a system that meets your specific requirements.

In our latest Coffee Break Webinar, we had the privilege of conversing with Matt Whittington from Hurst Boilers. He updated us on Hurst’s class-leading efficiency by optimizing heat transfer in their hot water and steam boilers. Spotlighting their different Scotch Marine offerings. These 45-minute webinars add to your professional development, are worth 1 PDH, and offer exclusive insights from top-tier professionals within the HVAC industry. To secure your place in the upcoming session, contact your SVL Sales Engineer for an invitation.

Harnessing Superior Efficiency: A Guide to Custom Hot Water and Steam Boilers from Hurst

In today’s ever-evolving industrial landscape, optimizing energy consumption remains paramount. Businesses constantly seek solutions to elevate efficiency and reduce their environmental footprint. Hurst Boiler, a leader in boiler manufacturing since 1967, offers a compelling answer with its premium series boilers.

A Legacy of Innovation: Hurst Boilers

Founded by Gene Hurst in 1967; Hurst Boiler’s roots lie in exceptional boiler service. Their focus on quality and customer satisfaction propelled them into boiler manufacturing in the mid-1970s. Today, Hurst Boiler stands tall as one of the nation’s leading fire-tube boiler manufacturers, delivering dependable and efficient boiler solutions.

The Scotch Marine Series: A Benchmark for Efficiency

The webinar sheds light on Hurst Boiler’s crown jewel – the Scotch Marine series. This series boasts a variety of boiler options, each designed to cater to specific needs while prioritizing efficiency.

• Series 500: The flagship, the Series 500, is a four-pass, water backed boiler that embodies superior efficiency. This premium boiler is ideal for those seeking top-of-the-line performance.
• Series 400: A worthy contender, the Series 400 is a three-pass, water backed boiler delivering efficiency comparable to the Series 500. It offers an excellent balance between performance and footprint.
• Series 250: Designed for space-conscious applications, the Series 250 is a two-pass, water backed   boiler that utilizes XID tubes to achieve impressive efficiency levels.
• Euro Series: This space-saving champion is a three-pass, water backed boiler featuring a larger Morrison tube. The Euro Series is cleverly designed to fit within a shipping container, making it ideal for scenarios with limited space.

Beyond Efficiency: The Advantages of Water Backed Boilers

The webinar delves deeper into the merits of water backed boilers over the dry back counterparts. Water backed boilers offer a clear advantage in terms of:

• Enhanced Heat Transfer: water backed boilers facilitate superior heat transfer, resulting in increased efficiency and lower fuel consumption.
• Simplified Maintenance and Reduced Costs: water backed boilers feature a more straightforward design that translates to easier maintenance and lower lifetime ownership costs.
• Improved Durability: The separate rear tube sheets in water backed boilers alleviate stress on the Boiler tube sheet, enhancing its durability.

StackMaster Economizer: An Innovation for Efficiency Enhancement

Hurst Boiler’s commitment to efficiency extends beyond the boiler itself. The webinar introduces the StackMaster economizer, an ingenious solution pre-packaged and integrated into the boiler’s smokebox. This clever design captures waste heat from flue gases, boosting boiler efficiency by 1.5% to 4%. Additionally, the easily replaceable coil design minimizes downtime in case of maintenance requirements.

A Commitment to Versatility and Support

Hurst Boiler recognizes the diverse needs of the boiler market. Their Scotch Marine boilers are available in both hot water and steam configurations, ensuring a perfect match for various applications. Furthermore, they provide a comprehensive line of aftermarket parts to guarantee long-term performance.

Investing in Efficiency with Hurst Boilers

By opting for Hurst Boiler’s Scotch Marine series, businesses can significantly increase efficiency, reliability, and productivity With Hurst’s commitment to innovation, quality, and customer support, Hurst Boiler empowers businesses to achieve their energy optimization goals.

Contact Hurst Boiler today to explore how their custom hot water and steam boiler solutions can elevate the efficiency of your operations.

New technologies are being deployed in facets of HVAC that would have been nearly unimaginable 20 years ago. We sat down with Victor Cincola from Accutrol, LLC at our latest Coffee Break webinar for an overview of how AccuValve is changing airflow systems.

SVL Coffee Breaks are 45-minute presentations from the leading innovators in the HVAC community. To stay up to speed on the latest developments in the industry, contact your SVL Sales Engineer for an invite to our upcoming sessions.

What are the traditional methods for airflow control?

There have historically been two basic technologies that are used to control the airflow to a space. Both have their pros and cons and applications to which they are best suited.

The first and most basic one of these technologies is a box with a single-blade damper and differential pressure airflow measurement. This is the basic setup you’ll find in VAV boxes. It is still a good choice for office environments because it’s economical and the space usually doesn’t experience large swings in airflow demand. That’s important because one of the significant limitations is that boxes like these are not linear devices, meaning they perform best at the high end of their specified airflow range.

The second technology is a mechanical Venturi valve. This was a preferred solution from the 1980s to the 2000s. It contains no airflow measurement because the airflow going through it is metered. As static pressure changes, the valve mechanically compensates to maintain the design cfm.

Are these technologies out of date?

No. There’s no one-size-fits-all solution in airflow and both technologies continue to be used successfully today. However, there have been technological advancements in this facet of HVAC that allow, for example, for greater control at lower static pressures and greater flexibility of placement and orientation.

Accutrol has seen the desire for energy efficiency and flexibility in airflow control. Owners want to run their systems at lower pressure, with less fan horsepower, while accurately measuring airflow in the system.

Accutrol’s AccuValve® with VorTek™ airflow measurement is the new alternative. What makes it different?

AccuValve is designed to deliver accurate airflow at a low pressure drop. This has a cascading effect — lower pressure means lower energy usage, not having to run fans so hard means less fan maintenance and longer service life, and ultimately, smaller fans and improved acoustics.

The valve also delivers precise, true airflow measurements without the need for a straight run. To measure airflow, you need a developed, repeatable airflow profile over the range you want to operate in. Straight runs are commonly used to accomplish this, but there are other ways. Compression is another.

No matter how the airflow comes into the AccuValve, the airflow is compressed into two sections and the airflow is fully developed at the flow sensor locations. It doesn’t matter how the valve is mounted or oriented, or if airflow is greater in one section. The measurements are measured in the two chambers separately and added together.

Then a set of control blades in one or both sections can restrict the amount of airflow going through the valve. Finally, a regain section at the end of the valve allows the airflow to decompress in an organized fashion, making the valve much more efficient.

Are the control blades on AccuValve any different than those of a single-blade damper?

The control blades on the AccuValve open and close at a different rate. This is why the airflow is measured in two chambers, because there may be times when the control blades create greater flow through one side and less through the other. The mechanical reason for this is to create a much more linear control in terms of flow through the valve and its position.

The idea is similar, although not entirely the same, to a two-thirds/one-third liquid valve that linearizes the flow through the valve.

AccuValve’s airflow sensing and the offset blades give the valve a large turndown, at least 10:1, sometimes even more, of excellent, linear airflow control. This means you don’t have to know the exact range in which you apply the valve. This is especially nice if you’re retrofitting a building and replacing mechanical Venturi valves. When you finally dial back the static pressure in the system, you won’t have to go back and recalibrate all the valves to compensate for the change in pressure.

What are the best practices for CO and NO₂ detection?

That was our question to Jennifer Thomas, the senior regional salesperson for INTEC Controls, at our latest 45-minute Coffee Break webinar. These monthly sessions are packed with information from the brightest minds in the HVAC industry and cover the latest innovations in all types of building systems. Contact your SVL Sales Engineer for an invite to our upcoming Coffee Breaks!

Headquartered in San Diego, INTEC Controls has been a supplier of high-quality sensors and controls for commercial HVAC for over 30 years. Jennifer gave our attendees a deep dive into the current state of CO and NO₂ detection systems.

What applications need CO/NO₂ monitoring?

Any enclosed space where vehicles are running. These include parking garages, package distribution hubs, vehicle maintenance facilities, car dealerships, and loading docks.

Also, boiler rooms and other spaces that house gas-burning appliances. Incomplete combustion problems can result in the production of carbon monoxide and other harmful gasses.

Why monitor for CO/NO₂?

Safety: This is the obvious reason. Carbon monoxide is an asphyxiant. It’s odorless, colorless, and dangerous if left unventilated. Nitrogen dioxide is a carcinogen and high levels risk long-term health effects for the occupants of these spaces.

Energy savings: Running fans at high speed 24/7 to ensure proper ventilation is expensive. With UL 2075-listed gas sensors, fans can cycle between standby airflow (>0.05 cfm per ft²) and full-on airflow (>0.75 cfm per ft²) when it’s necessary.

Gas sensor studies tell us that the typical garage only needs full-on airflow during high-traffic periods — a few minutes in the morning, lunch hour, and evening. Including gas sensors in your building controls ensures your ventilation fans don’t waste energy.

HVAC ROI: A corollary of energy savings is the ability to save wear and tear on your fan equipment, extending its lifespan.

What do building codes require for gas detection?

The International Mechanical Code (IMC) contains various prescriptions for gas detection. Since 2018, the current code (IMC 2021 sec. 404.1) for mechanical ventilation systems for enclosed parking garages allows for either 24/7 operation of fans at full flow or controlling the airflow specifically using UL 2075-listed gas sensors.

UL 2075 is a rigorous performance standard for gas sensors. First released in 2006, it’s a costly, long-term certification process, and not every sensor package on the market has received that rating (meaning they are not in compliance with the IMC 2021 for this application).

Pay close attention to the wording used on gas sensors. There is a difference between being “UL-listed” versus one that says UL- “recognized,” “compliant,” or “approved”. The word “listed” specifically matters for code compliance and the entire package must be listed (not just certain components).

Where should gas detection sensors be placed?

The maximum coverage area for CO/NO₂ sensors is 7,500 square feet (a 50-foot radius). It depends on where you can physically mount the sensors and whether there are obstructions to the airflow, but the optimal location is 5 feet above the finished floor, right in the breathing zone.

In large, open areas that don’t have a mounting location in the breathing zone (say, an aircraft hangar that’s been converted to car storage), you should think about creative solutions, like installing posts to mount the monitors.

What is the control strategy for gas detection?

Fans should run at the standby airflow rate to satisfy the minimum code-required cfm/ft² for that space. Once any sensor detects 25 ppm CO or 1 ppm NO₂, the fans run at high speed to ventilate the harmful gasses.

The design strategy you choose for hydronic pumping arrangements will affect both your installed first costs and energy costs over time. That was the message from Tony Furst, director of applications engineering for Armstrong Fluid Technology, at a recent Coffee Break webinar.

At least once a month, we invite a subject-matter HVAC expert to our webinar series to explain the most important topics in the industry. Ask your SVL sales engineer for an invitation to our upcoming sessions.

What is parallel pumping?

In contrast to hydronic systems with one operating pump and one standby pump, a parallel pumping system has two or more pumps operating simultaneously with proper staging.

In this arrangement, the flow increases but the head pressure stays the same (if the design flow is 1,000 gpm, each pump will deliver 500 gpm at the design head).

All the pumps must be identical in a parallel pumping design. When you look at your pump curves, the system curve must intersect both the single pump and parallel pump curves. If they don’t, and you reduce the number of running pumps, you risk cavitation.

The motor is sized based on the single pump operating point. If it doesn’t cross the system curve, the motor will overload. Note that we’re talking about operating pumps. If you have three or four pumps running in parallel, the single pump curves don’t need to cross the system curve because the system won’t ever run on just a single pump.

How does parallel pumping reduce operating costs?

At some point, the efficiency of a pumping system peaks and then begins to decrease. But the more pumps you run, the flatter those efficiency curves get. When you have four pumps in parallel, you can maintain peak efficiency over a much wider operating range than with a single or even two pumps in parallel.

Thus, parallel pumping is about maximizing pump efficiency with smaller horsepower motors and thus driving down operating costs.

What about redundancy? Does parallel pumping allow for duty pumps and standby pumps?

Compared to a two-pump standard design (duty/standby, 100% flow each), a two-pump parallel design (each sized for 50% flow) will satisfy the system requirements with smaller motor horsepower.

A two-pump parallel design with each sized for 75% flow might be a good idea if you think you might expand your system in the future. Three-pump and four-pump designs are also an option for further redundancy.

Redundancy is a common concern with parallel pumping. But ask yourself: do you really need a true standby pump for redundancy?

Even if one pump fails in a parallel system, the other pump will still deliver ~80% of the design flow. Perhaps for some critical applications like hospitals and data centers, that’s not acceptable. But for most applications, according to ASHRAE, coils can still deliver up to 95-98% of the design heat transfer on just 80% of the design flow rate.

The question becomes, if that is the worst-case scenario, how much redundancy does the application need? Remember that maximizing redundancy may be at odds with other design criteria like overall project budget or energy efficiency. It may also have additional first costs and annual operating costs that may not be at all necessary.

But doesn’t it cost more upfront to buy and install more pumps?

This logic doesn’t hold with vertical inline split-coupled pumps from Armstrong. Typical horizontal end-suction installation requires alignment in the field, which drives up costs. Armstrong’s pumps are aligned at the factory. They also don’t require a concrete inertia base, which is expensive and needs to be grouted to reduce vibration.

Armstrong’s vertical inline pumps are instead supported by the piping and don’t require flex connectors. Their VFDs are pre-mounted and factory-wired with the proper cabling between the motoring and the drive. Everything is assembled and tested in the factory. And because there are no bearings in the pump, only in the motor, maintenance is a breeze. You can take the motor off and not touch the wet end.

Because you eliminate all these installation requirements, the piping is a little smaller, and the motor sizes are also smaller, a parallel pumping arrangement does save on total first costs.