| Here are the proper steps to designing an efficient and | | | | supply and return piping was the wrong diameter and |
| cost effective heating system: | | | | or the ducts and/or diffusers were the incorrect size. |
| 1. Through in depth discussions with the GC and building | | | | 3. The number of installed zones (each zone has a |
| owner, determine exactly what the building owner | | | | thermostat, so count tally them up and that's the |
| expects from the new heating system - what type of | | | | number of zones in your system) was either too many |
| system will it be? There are numerous options for | | | | or, less likely to cause excessive fuel consumption, too |
| system types and the type of fuel it will utilize. What | | | | few. |
| level of efficiency will the system be capable of? | | | | 4. The installed zone(s) had too much radiation |
| What level of equipment quality is expected? How | | | | capacity connected to it/them. Too much baseboard |
| many heating zones are desired? How will potable | | | | radiation on a forced hot water zone will cause a heat |
| water will be heated - through the boiler and | | | | imbalance in the building and hot and cold spots will |
| indirect-fired water heater, or a separate heating | | | | ensue. The solution is to split the zone into more |
| source like a direct-fired water heater - gas, electric, oil, | | | | "loops". |
| or solar? In the case of an "indirect" water heater, I will | | | | 5. Ducts or pipes were not insulated in unconditioned |
| be sure to add the requisite BTUs per hour for the | | | | spaces. You really don't want to inadvertently heat |
| domestic hot water as needed. Basically, all relevant | | | | basements, attics, crawl spaces and the like, therefore, |
| information will need to be conveyed with | | | | the ducts or pipes need to be insulated. Ducts also |
| person-to-person discussions, and the HVAC | | | | need to be sealed to prevent air escape. |
| subcontractor should be able to drive the discussions | | | | 6. The installer did not set up the combustion process |
| to the point that all questions will be satisfactorily be | | | | to achieve the carbon dioxide, oxygen, smoke, gross |
| answered so he can proceed to the next step. | | | | stack temperature and draft levels that the |
| 2. The HVAC sub needs to obtain a complete set of | | | | manufacturer intended. Too high a stack temperature |
| working construction drawings that include all floor | | | | (too much negative draft in the smoke pipe) means |
| plans, elevations drawings, window, door and insulation | | | | too much heat is escaping up the chimney. Too low a |
| schedules, and geographical orientation. | | | | CO2 percentage of flue gas means the fuel isn't being |
| 3. The HVAC designer will then interpret the drawings | | | | completely combusted (at least as much as is possible |
| and harvest all of the necessary data from it to be | | | | with the equipment). Too much smoke in a smoke test |
| used in the heat loss calculation software. The | | | | means the boiler or furnace will "soot up" quickly. An 1 |
| software will tell him how many BTUs/hour the building | | | | 8" of soot is equivalent to an inch of fiberglass |
| will require on the coldest day and will break the total | | | | insulation. You don't want insulation on the heat |
| down by individual room "loads". | | | | exchanger, otherwise the heat generated by |
| 4. The designer will then select the proper equipment | | | | combustion will not transfer into the heating medium - |
| based on fuel type, "net" heating output capacity (in | | | | air or water - and the heat will go up the chimney in |
| BTUs/hour) and how the heating appliance will be | | | | excessive stack temperature. |
| vented - through a chimney, sidewall-vented or | | | | 7. In the case of oil burners and power gas burners, if |
| power-vented out the side of the building or | | | | the burner output capacity in BTUs was not matched |
| direct-vented through the roof. He will also account for | | | | to the boiler/furnace "input capacity" then the burner |
| quality and efficiency rating. | | | | will either short cycle (burner output too great), or the |
| 5. Then the heat distribution aspect of the design will | | | | burner will never shut off (burner output too little). |
| be worked through. For FHW, he will determine pipe | | | | 8. The installing contractor selected a boiler with a |
| sizing and type, circulator (the 'pump' that moves hot | | | | temperature limit control that maintains temperature in |
| water from the boiler to the terminal units) | | | | the boiler that is too great for the application. The |
| performance characteristics, flow control devices and | | | | installer incorrectly set the temperature limits in the |
| terminal unit type(s) and sizes. | | | | aquastat (boiler) or fan and limit control (furnace). Too |
| 6. The designer will then choose the control systems | | | | much fuel and electricity will be consumed as a result. |
| based on number of zones, energy-savings and | | | | 9. The wrong flow capacity circulators were selected |
| safety and code requirements. | | | | and installed in the forced hot water system. Not |
| 7. The fuel storage type and capacity will be selected. | | | | enough heat is transferred to the space (the burner will |
| 8. A total cost estimate will be generated and a | | | | short cycle) or electric consumption will be too great. |
| proposal listing all of the major components will be | | | | 10. The burner - gas or oil - metering device (orifices |
| drafted and submitted. | | | | with gas; nozzle with oil) was incorrectly selected, |
| This is a basic list of steps. In reality, there are so many | | | | which usually means the wrong boiler/furnace or |
| details to creating a competent design and estimate | | | | burner was incorrectly selected and installed. Almost |
| that delineating all of them goes beyond the scope of | | | | always, the manufacturer of the heating equipment |
| this article. The most important point is that the heat | | | | charges their engineering department with the task of |
| loss calculation must be competently performed | | | | Research and Development to determine what nozzle |
| before any other design step can be taken. The other | | | | of orifice(s) are correct and set up the burners to |
| important thing is that the proper equipment be | | | | include the correct ones with their burner/boiler or |
| selected that answers to the heat loss calculation. If | | | | furnace. Nevertheless, incompetence can get in the |
| the equipment heating capacity is guessed at, then the | | | | way and that is often messed up in the field. |
| system will most likely be over-sized...for the life of the | | | | 11. The installer did not set the correct metering rate for |
| system. Next is as important - the efficiency of the | | | | the requisite gas input rate for the burner. This means |
| equipment is crucial to future fuel consumption and a | | | | that he did not adjust the "manifold pressure" for the |
| true professional HVAC system designer will promote | | | | gas after the gas valve on the gas burner. With |
| the highest efficiency available. Spending a few | | | | today's high efficiency, multi-stage firing burners, this is |
| hundred dollars initially is always more advantageous | | | | a very technical set up feature that absolutely must be |
| financially than forever burning more fuel due to poor | | | | done. In certain cases, a gas explosion can result if the |
| efficiency. Consider higher efficiency equipment as an | | | | manifold pressure in each firing stage is not set |
| investment in future fuel savings. | | | | correctly. This must always be done in the field after |
| If any of the steps outlined above are skipped, then | | | | complete system installation. |
| greater operating and service costs will result. Some | | | | 12. The installer did not follow the manufacturer's |
| HVAC subs do not design the systems they install, | | | | installation and/or service instructions to the letter. Too |
| their equipment/parts suppliers do the calculations for | | | | much fuel or electricity will be consumed, too much or |
| him and he automatically believes they did the | | | | too little heat will be generated, and/or a safety issue |
| calculations right. Often a lot of rounding up gets done | | | | will result. |
| in the HVAC design world, as nobody wants to be left | | | | 13. Water through pipes and/or air through ducts was |
| holding the bag if too small a system is installed, then | | | | not properly balanced, causing heating imbalance in the |
| doesn't sufficiently heat the house on the coldest days | | | | conditioned space and excessive electrical |
| of the year. And that rounding can account for 25% of | | | | consumption by circulators and blowers.The bottom |
| the system capacity - it will be too over-sized and | | | | line is if the designer did not properly design the |
| cost the building owner more money to heat. | | | | system, then: |
| I can't express enough how many HVAC systems are | | | | |
| incorrectly sized and designed. I see them every week | | | | 1. Too much electricity and/or fuel will be consumed. |
| I am out in the field. It is more normal for systems to | | | | 2. The system will most likely never work correctly. |
| be designed incorrectly than to be designed correctly. | | | | 3. The system can become a danger to people and |
| Yes, I repeat: most heating systems are designed | | | | property. |
| incorrectly and burn too much fuel! | | | | 4. Consequential damage costs can result. |
| While plumbers and HVAC companies are often | | | | 5. Civil litigation costs can be expected. |
| incompetently designing and installing heating systems, | | | | 6. The installed cost of the system will not be |
| fuel companies are more often intentionally designing | | | | accurately represented. |
| systems to burn the greatest amount of fuel their | | | | 7. The environment will suffer. |
| systems can get away with. Again, not all fuel | | | | 8. The building owner will pay with his money, time and |
| companies are doing this, only the unethical ones are. | | | | frustration level.The bottom line is if the installer did not |
| Still, there is a great amount of ignorance in heating | | | | properly install the system, then: |
| system design. HVAC sales engineers (like myself - | | | | |
| see my resume at my website) are few and far | | | | 1. Too much electricity and/or fuel will be consumed. |
| between. Companies will pay great money to acquire | | | | 2. The system will most likely never work correctly. |
| a competent sales engineer. Conversely, HVAC | | | | 3. The system can become a danger to people and |
| companies aren't looking for them because they know | | | | property. |
| it is a futile search. | | | | 4. Consequential damage costs can result. |
| Residential building owners are the most taken | | | | 5. Civil litigation costs can be expected. |
| advantage of by companies through deliberate and | | | | 6. The installed cost of the system will not be |
| unintended shoddy heating system design, installation | | | | accurately represented. |
| and service. This is true because homeowners do not | | | | 7. The environment will suffer. |
| have the desire to learn about their heating system, | | | | 8. The building owner will pay with his money, time and |
| nor the time to get over the learning curve. Therefore, | | | | frustration level.The bottom line is if the service |
| they do not know the right questions to ask of a GC, | | | | technician did not properly service the system, then: |
| HVAC or fuel company. They often are meticulous in | | | | |
| scheduling the annual cleaning/inspection of their | | | | 1. Too much electricity and/or fuel will be consumed. |
| heating system, yet lack the important knowledge to | | | | 2. The system will not work correctly until a technician |
| determine if the cleaning was done right. They will | | | | who knows what he is doing fixes the problem(s). |
| never know if the system was designed and installed | | | | 3. The system can become a danger to people and |
| right and if the technicians who have worked on it | | | | property. |
| through the years knew what they were doing. Any | | | | 4. Consequential damage costs can result. |
| incompetence along the lifespan of the system, from | | | | 5. Civil litigation costs can be expected. |
| design to the last service call before the system is | | | | 6. The service cost of the system will not be |
| replaced, will cost the homeowner more money. | | | | accurately represented and will always end up costing |
| Mostly, homeowners are oblivious to the extent they | | | | more. |
| are being ripped off! | | | | 7. The environment will suffer. |
| Here's a rip-off scenario of a different kind. People | | | | 8. The building owner will pay with his money, time and |
| think they have to spend $30,000 to save a grand a | | | | frustration level.The bottom, bottom line is any of the |
| year in fuel cost! They are lead to believe this routinely | | | | above bottom lines can be combined and the result will |
| by energy auditing "professionals". In a blog post to | | | | be a veritable nightmare for the building owner. I see |
| come I will explain how "energy auditing" firms are | | | | the outcome on a regular basis and this is why people |
| duping their clients into believing they need some kind | | | | hire me - to fix these screw-ups. At least 90% of my |
| of sophisticated analysis to determine how their client | | | | work is generated from the screw-ups of other |
| can save money on fuel, and that they need high tech | | | | HVAC designers, installers and service technicians. |
| HVAC equipment to save money on energy costs. | | | | This is not to say that we don't all make mistakes. We |
| This is a huge scam, considering the energy auditor will | | | | do, I do. Some who make mistakes offer no solutions |
| charge tens of thousands of dollars to evaluate their | | | | or apologies for their mistakes. I do. |
| building before any energy efficiency measures are | | | | So what can you do when you suspect that someone |
| carried out. They fly under the flag of the monetary | | | | has made mistakes with the design, installation or |
| incentives for the building owner provided for in the | | | | service of your heating system, or any HVACR |
| The American Recovery and Reinvestment Act of | | | | system in general? Contact me. This is why I offer |
| 2009 - The "Economic Stimulus Package". | | | | design, installation, service, consulting and expert |
| Recently, I was contacted (through a referring party | | | | witness services in the Heating, Ventilation, Air |
| who worked for the New Hampshire Public Utilities | | | | Conditioning, Ventilation, Refrigeration, Humidity Control, |
| Commission) by a woman who had been a | | | | Exhaust and other aspects of the "HVAC" realm. |
| policymaker with the same state agency for 20 years. | | | | There's a huge market for it. |
| She inquired about converting 3 heating systems in 2 | | | | Here's what you need to do to prevent the mistakes |
| apartment buildings to higher efficiency gas-fired | | | | from being made in the first place: |
| boilers, so she could do her part in reducing her carbon | | | | |
| footprint and qualify for benefits under the U.S. | | | | 1. Research your prospective HVAC installing |
| "Stimulus Package". I told her the ramifications of | | | | contractor's background - ask for references, his |
| changing her chimney-vented boilers to direct-vented | | | | training history, employment history, his website, his |
| types would be a costly endeavor, approaching | | | | specialization(s), if any. |
| $10,000 apiece. I also told her that I could make her | | | | 2. Ask your installing contractor, or general contractor, |
| cast iron mid-efficiency FHW boilers burn as much as | | | | who is responsible for the design of your system. If |
| 15-30% less gas. Of course, she was all ears. She | | | | they say their parts supplier, tell them you are not |
| hired me for a couple of grand to install temperature | | | | interested. You must hire an installer who does his own |
| modulation controls on the 3 boilers and make a few | | | | designs. That way, if things go wrong he is solely |
| other modifications. The end result means she will | | | | responsible for the system shortcomings. In the worst |
| spend about the same on fuel as the new technology | | | | case scenario, you do not want to have to sue multiple |
| high efficiency boilers would require, and she got these | | | | companies/individuals, or your legal bills will preclude |
| modifications for about $28,000 less! | | | | your success. |
| Commercial building owners are generally more | | | | 3. Make sure you get a copy of the heat loss |
| required by job description to know important things | | | | calculations...in their entirety! If they can't offer you a |
| like, the benefits of heat loss calculations, proper | | | | copy (this means they have not done the calculations |
| equipment output capacity and the steps required of | | | | in Wrightsoft, Elite, or an equipment manufacturer's |
| technicians doing maintenance. This is not to say that | | | | proprietary software), then fire them before you hire |
| commercial building owners are not somewhat in the | | | | them! |
| dark, too. Not all commercial buildings are managed by | | | | 4. Ask your installing contractor to see his portfolio of |
| people who are wise to HVAC technologies and the | | | | past installations and the names and contact |
| tricks-of-the-trade, shall we say. Nevertheless, | | | | information of his customers with those systems. If he |
| commercial systems naturally consume greater | | | | can't provide that information, then move on to the |
| amounts of fuel - the space to be heated is bigger | | | | next installer who can. |
| than homes - and when they burn inefficiently the | | | | 5. Ensure that you speak directly with the installing |
| wasted fuel is also greater than that wasted in | | | | contractor. If your general contractor/builder does not |
| residential applications. Therefore, it is more imperative | | | | allow this...fire him before you hire him! |
| for commercial building owners to make sure they are | | | | 6. When you speak directly with the prospective |
| getting the correct answers from their HVAC | | | | installing HVAC contractor, make sure you discuss the |
| professionals. | | | | type of fuel you intend to burn; the type of venting |
| Like the fox that guards the hen house, your fuel | | | | method you will be using (masonry chimney, high |
| company is not unlike the fox. The more fuel your | | | | temperature metal chimney; sidewall/direct-vent, or |
| heating system uses, the more money you pay your | | | | "ventless") and the efficiency range (mid-efficiency or |
| fuel supplier. It's logical then to believe that the greatest | | | | high-efficiency) of the equipment that you desire. Also, |
| amount of fuel they can sell you is what they | | | | do some research on heating system types, product |
| endeavor to sell you. Like the fox scheming to eat the | | | | types, brand names, furnace and boiler material |
| hens, fuel companies can and do design and service | | | | construction types (cast iron, steel or cast aluminum) |
| heating systems in ways that demand the burner | | | | and the approximate costs for each versus what your |
| burns more fuel than is otherwise necessary to heat | | | | return on investment (ROI) will be for each. |
| your building. All they have to do is skip the heat loss | | | | 7. Pick your installing contractor's brain for his reasons |
| calculation and pick an inefficient, oversized | | | | for selecting the types and brands of the equipment |
| American-made boiler and sell it to you. You trust them | | | | and materials who chooses to install. If his reasons |
| and are confident that the new boiler will heat your | | | | don't sound quite right, then there is a red flag. Get |
| house reliably. You hope you will save money on fuel, | | | | other installer's opinions and recommendations and go |
| but at least it won't break down soon. Unfortunately, | | | | with your gut feeling. |
| the fuel company salesman didn't tell you the new | | | | 8. Tell your general contractor/builder that you want |
| boiler is a single-pass flue design and has a gross | | | | several alternate HVAC installer quotes...then go with |
| stack temperature of 450 degrees. He also didn't tell | | | | your gut feeling on which one to select for your |
| you that you could have bought a European boiler with | | | | project. |
| a triple-pass heat exchanger and resulting 300 degree | | | | 9. Educate yourself as much as you can with all that |
| gross stack temperature. He also didn't offer to sell | | | | you can stand to know about heating systems. "An |
| you a temperature modulation control and an | | | | Educated Consumer is Our Best Customer!" You've |
| indirect-fired water heater. Instead, you got a boiler | | | | heard that slogan before. Be that educated consumer. |
| with a "tankless" coil (for domestic hot water) that | | | | 10. Never buy a system because it was the low bid! |
| requires the boiler maintain constant temperature 24/7 | | | | You virtually always get what you pay for. "Pay Now |
| all year long. All the while, heat constantly escapes up | | | | or Pay Later!" You've heard those cliché's as well. |
| the chimney into the atmosphere. | | | | 11. Let me design your heating/HVACR system(s). |
| What if you are considering the purchase of a building? | | | | Then you will know you covered all the important |
| You walk-through the building and make note of as | | | | bases. I will provide you with a heat loss analysis, Bill Of |
| much detail as you are able to in a limited number of | | | | Materials (estimate for every single part that your |
| walk-throughs. You calculate the cost of things like | | | | system(s) will be comprised of, down to the last screw |
| paint, landscaping, obvious mechanical systems repairs | | | | and wire nut), Proposal with all the essential information |
| and the like, but you most likely know very little about | | | | and legalese, in an understandable presentation, and |
| heating technology, but do you know how fuel efficient, | | | | any and all product specifications that comprise your |
| or inefficient the heating system is? You can ask what | | | | system. |
| the past fuel costs have been, but without knowing | | | | 12. If you don't hire me for your designs, estimates or |
| what the infiltration rate of the building is and how | | | | proposals, then let me review those of your installing |
| many BTUs are required to heat the building on the | | | | contractor so I can pinpoint any shortcomings. |
| coldest day of the year, then you will not be able to | | | | 13. If you live in my area of business, then consider me |
| make any educated conclusions about the heating | | | | for the system installation and service. |
| system's efficiency and effectiveness. Therefore, you | | | | 14. If you hire someone else, then let me inspect his |
| will not be able to accurately predict the cost to heat | | | | work...before you make the final payment to him! That |
| the building. If you buy the building you will find out in the | | | | way you will have leverage if he did something that is |
| first year what the heating system consumes in fuel, | | | | wrong and the system won't perform as intended. He |
| assuming the weather is typical winter weather. | | | | will come back to fix a problem if he knows he will get |
| Here are the mechanical reasons behind high fuel and | | | | paid when the problem is fixed. |
| electricity cost: | | | | 15. Make sure that the installed system is inspected by |
| | | | the local Municipal mechanical inspector and/or the Fire |
| 1. No one did a heat loss calculation before the heating | | | | Chief. But don't rely too heavily on the "rubber stamp |
| system was installed and they guessed at the BTU | | | | of approval" from the inspector, as a good majority of |
| capacity of the heating appliance (boiler or furnace) | | | | inspectors have no idea what they are even looking at. |
| and/or the radiation (baseboard or duct and diffusers | | | | 16. Check with your state's Public Utilities Commission |
| sizes) capacity was undersized. A boiler/furnace that | | | | to see if they prescribe and enforce energy efficiency |
| is too big, as discussed, will short cycle and consume | | | | measures and codes. You will be surprised how many |
| too much fuel like city driving. A boiler or furnace that is | | | | installers do not know of or follow these prescribed |
| too small will not adequately heat the building, the | | | | codes and measures, or if they even exist.I could tell |
| conditioned space will not reach the desired | | | | you volumes more about HVAC systems efficiency |
| temperature so the thermostat will never be satisfied | | | | and safety, but that will have to be seen in past and |
| and the boiler/furnace will never shut off - and burn | | | | future Blog postings. In the meantime, good luck and be |
| too much fuel. | | | | educated! |
| 2. The boiler or furnace was installed incorrectly. The | | | | |