FACILITY OWNER AIMS FOR GREEN AND GETS LEED® PLATINUM:FULTON PRODUCTS CONTRIBUTE TO

HIGH HVAC EFFICIENCIES AT FACILITY RETROFIT

CASE STUDY: ENVIRONMENTAL WAY_2011-0815

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TWO NATURAL GAS-FIREDFULTON PULSE BOILERS WERE INSTALLED

TO SHARE THE HEATING LOAD

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THE PROJECT AT ENVIRONMENTAL WAY

Unoccupied for a decade, the Environmental Way building had a system that consisted of ineffi cient cast-iron sectional boilers before the rehabilitation project began. Bowles knew a critical component of his project would be to reduce the HVAC system’s environmental footprint as well as its operational costs.

In addition, the pre-renovation system drew 9 amps per boiler for the power burner motors, Bowles said. He knew he could do better on a system’s electrical consumption.

“Our focus from the beginning was to utilize as many of the existing building features as possible,” Bowles said. “HVAC and electrical are often two of the most costly components of a retrofi t project, especially one that wants to ‘go green’.”

Decisions needed to be made about what to keep and refurbish, and what to completely replace. As part of the comprehensive rehabilitation plan for the facility, Bowles contacted Eric Hobbs, Vice President of Weeks-Williams-Devore, Inc. in Matthews, NC., a Fulton authorized manufacturer’s representative. Bowles shared the Environmental Way concept with Hobbs, indicating that when the retrofi t project was complete, he intended to seek U.S. Green Building Council Leadership in Energy and Environmental Design (LEED) Green Building Rating Systems™ certifi cation at its most elite level – Platinum.

David Bowles, owner of Environmental Services of Charlotte, Inc., purchased the empty 70,000 square-foot IBM building in 2009. A mechanical and electrical contractor, Bowles saw the shell of a building as the perfect place to carry out his vision: the creation of a multi-faceted showcase of “green building” capabilities.

“The building had ‘good bones’,” Bowles said. “I saw a structure that could

become one of the most energy effi cient in the region, without necessarily breaking the bank.”

Aptly re-named Environmental Way, the facility was fully rehabilitated in 2009 and 2010, and now serves as a model of cutting edge and integrity-based environmental design solutions that result in cost savings for the building’s owner – particularly in the realm of hydronic heating.

DAVID BOWLES, BUILDING OWNER

FOR DAVID BOWLES, A FORMER IBM CORPORATE FACILITY IN CHARLOTTE, NORTH CAROLINA WAS MUCH MORE THAN AN ABANDONED EYESORE. IT WAS AN OPPORTUNITY.

With broad expertise in industrial and commercial combustion products, hydronic and steam boilers, along with air handling equipment, Hobbs was eager to be a part of Environmental Way’s vision.

“DAVID WANTED TO UPGRADE THE EXISTING BOILER SYSTEM TO AN ENVIRONMENTALLY-FRIENDLY BOILER SYSTEM,” HOBBS SAID. “I KNEW FULTON WOULD BE THE PERFECT FIT.”

Hobbs suggested the building would be best served by the installation of two Fulton Pulse Hydronic Boilers to replace the aging system. With its ultra high effi ciencies (up to 99 percent), low electrical consumption (less than 1 AMP), low maintenance cost and simple design, the Pulse Condensing Hydronic

Boiler system was the optimal solution for the project, Hobbs said.

“We have sold the Pulse boilers and water heaters since they were introduced to the market (more than 20 years),” Hobbs said. “We have had a lot

ultimately increases equipment life. By designing the control logic to minimize the number of times a specifi c unit cycles, the wear on the boiler system is minimized and the equipment life cycle is greatly extended.

In addition, the system responds to outdoor temperature readings and adjusts the loop setpoint accordingly. Hydronic systems are confi gured to maintain building temperatures at design temperature, ensuring there is enough heat on the coldest days. But if the outdoor temperature is warmer than the design temperature, the boiler plant has too much capacity. With a properly designed control system in place, lower hydronic loop temperatures will be used to generate higher system effi ciencies – which in turn means signifi cant energy savings.

HOW PULSE HYDRONIC HEATING TECHNOLOGY SAVES MONEY AND IMPROVES SUSTAINABILITY

Pulse combustion technology is recognized in the HVAC industry as one of the most effi cient ways to burn fuel. A pulse is defi ned as one cycle of ignition and combustion of a gas/air mixture in a specially designed combustion chamber, increasing energy effi ciency.

The Pulse boiler also reduces electrical consumption associated with burning fuel. The pulse combustion process is naturally aspirating and does not require a blower motor for operation. An assist fan is used for pre- and post-purge only and turns off once combustion has been established.

At Environmental Way, the Pulse boilers are being controlled by the ModSync Sequencing System from Synex Controls. The ModSync’s cutting-edge technology helps users optimize boiler effi ciency for hydronic, steam boiler, and thermal fl uid heater installations. With the sequencing system in place, Environmental Way has the capability to minimize cycling and maintain even operational usage across each boiler in the heating plant – which

of experience with the reliability of this product.”

In addition, Hobbs recommended the installation of a Synex Controls color touch screen ModSync™ sequencing system. The ModSync was custom-confi gured for the specifi c needs of the installation to operate the condensing boilers at their optimized effi ciency levels.

One year later, both natural gas and electricity costs at Environmental Way were reduced, Hobbs said, all while handling a signifi cant increase in the occupied facility temperature of 72°F (22°C) rather than the unoccupied temperature of 50° F (10°C). The Pulse boilers draw approx. 0.75 Amps during run mode (about 90 Watts).

The Fulton Companies972 Centerville Road, Pulaski, NY 13142Call: (315) 298-5121 • Fax: (315) 298-6390

www.fulton.com

environmentalway-csch-2011- 0815

The heat transfer innovators.

hydronic and thermal fl uid heat transfer systems. Backed by over 60 years of research, innovation and experience, Fulton is building on a tradition of success and is focused on improving life through heat transfer equipment and energy management solutions. For additional information about Fulton, please visit www.fulton.com.

SYNEX CONTROLSSynex Controls is an industry leader in the development of customized control solutions for Commercial and Process markets. For additional information about Synex Controls products, please visit www.synexcontrols.com.

STORY LINKS:Fulton Companies website:www.fulton.com

Synex Controls website:www.synexcontrols.com

Environmental Way website:www.environmentalway.com

Weeks-Williams-Devore, Inc. website: www.wwd-inc.com

U.S. Green Council website:www.usgbc.org

with others, Bowles is developing an internet “dashboard” to permit others to get live, up-to-the-minute data on the building’s effi ciencies – including the boiler system’s activities, he said.

“It will give people the opportunity to really see what goes on with the equipment used throughout the building,” Hobbs said. The interaction of the equipment and the design are an integral part of the mission of Environmental Way, he said – one that can serve as a model for others seeking the same outcome.

“The partnerships that Environmental Way has been able to develop with Fulton and Weeks-Williams-Devore Inc. have been crucial,” Bowles said. It has helped us to achieve our goals as one of the most energy effi cient commercial building retrofi ts in our region.”

For more information on the project, visit

WWW.ENVIRONMENTALWAY.COM

THE FULTON COMPANIESWith manufacturing facilities in the United States, Great Britain and China, Fulton is a global manufacturer of steam,

THE RESULTS AT ENVIRONMENTAL WAYThe hydronic heating system and ModSync installed at the Environmental Way building are among many of its amenities: wind generators, “off -the-grid” battery backups, recycled building materials among them. The facility is expected to earn its LEED Platinum status in 2011, and has quickly become a centerpiece of design – one that has brought visitors from far and wide to gather ideas and information, Hobbs said. It also has become a meeting place for green movement industry innovators, including seminars and symposia on green building design.

According to B. Scott Counts, P.E., LEED® AP for Optima Engineering in Charlotte, NC, the benefi ts of the Fulton system at

Environmental Way are green for both

the environment and the wallet.

“In order to achieve a LEED certifi cation with an existing building, typically all the HVAC systems have to be replaced and new high-effi ciency HVAC systems installed,” Counts said. “The new boilers that have been installed are not only highly effi cient, but they also have a modulating gas input. Over the life of the system the owner will see a substantial savings in heating energy cost resulting from a higher effi ciency boiler with the ability to turn down the gas input to meet the actual heating demand.”

According to Bowles, the boilers contributed to LEED points under the program’s Optimizing Energy Performance calculation. That’s because in addition to the electrical savings mentioned, the new boilers provide an estimated 20% increase in thermal effi ciencies (based on natural gas usage) over the old equipment, Bowles said. The old system operated at 75-78% thermal effi ciency; the Pulse boilers are operating at up to 98% thermal effi ciency.

As part of the Environmental Way commitment to extending its experiences