UnderstandingINDUSTRIAL HVAC

HVAC

Contents

Why HVAC Matters

Industrial and Commercial HVAC

Industrial HVAC

What Is a Severe Duty Environment?

Common Hazards and Corrosive Chemicals

HVAC and the Internet of Things

Four Things You Need to Know When Choosing an HVAC System

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Whether you’re working in an

office building or a severe duty

petrochemical site, the presence

of an effective HVAC system can have a truly life-

saving impact, especially in

hazardous and toxic

environments.

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Why HVAC Matters

There’s a lot of industry jargon in HVAC.

When the time comes to purchase a new HVAC system, you’re guaranteed to come across technical terms such as psychrometric, purge and pressurization, true redundancy, and countless others. With time and experience, you gradually begin to learn the critical meanings and functions behind these terms and develop a working understanding of what exactly the Heating, Ventilating, and Air Conditioning (HVAC) industry is all about.

You might learn that “through-the-wall” HVAC unit designs allow maintenance on the unit to be completed from inside the conditioned area—an important advantage in hazardous environments and in raised control rooms. You might also learn that horizontally-mounted backwardly-inclined blowers are more energy-efficient and quieter than standard blowers. You might even learn that HVAC systems are used in just about every industry from wastewater treatment to mining to food processing.

There’s a lot to learn about HVAC, but when it comes down to it, there’s only one thing you need to know to truly understand its purpose:

Whether you’re working in an office building or a severe duty petrochemical site, the presence of an effective HVAC system can have a truly life-saving impact, especially in hazardous and toxic environments. HVAC systems help to ensure the health, safety, and overall well-being of every person who comes to work. They are designed to perform tirelessly behind the scenes to instill a sense of confidence and peace of mind among those who depend upon their critical functions.

With a purpose this weighty, it is important to learn the most critical aspects of HVAC in order to ensure the proper systems are chosen to keep people and resources safe in a variety of applications.

The following eBook is a resource that will introduce (or re-introduce) you to some of the most common, important aspects of industrial HVAC. The information gained from these pages will help you to further understand HVAC in order to make an informed and confident decision when choosing your next HVAC system.

HVAC is about PEOPLE.

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Industrial & Commercial HVAC

There are multiple factors to consider when it comes to choosing an HVAC system that will meet the needs of specific applications. However, before considering the characteristics and variables of individual systems, one of the best places to start is understanding the basic difference between the industrial and commercial markets HVAC systems serve.

While the line between “industrial” and “commercial” is often blurred and can be difficult to define, the following is generally a good rule of thumb for comparison.

As the name implies, applications tend to focus on heavy duty industrial environments, such as refineries, wastewater and sewage treatment plants, mining facilities, and pulp and paper mills, among many others. Industrial HVAC systems rely upon heavy grade, high-quality materials and incorporate solid state electrical components. These systems are very rugged and can withstand the demands of harsh environments. Industrial HVAC systems are often installed to cool process equipment rather than personnel.

Applications tend to focus on retail environments such as office buildings, retail stores, and restaurants. However, commercial applications can also include schools, hospitals, hotels, and physical fitness facilities, among countless others.

The following section provides a breakdown of the various industrial HVAC systems. To learn more about whether an industrial HVAC system is the optimal choice for a specific application you have in mind, click the LEARN MORE link to the left.

Industrial

Commercial

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Industrial HVAC

Industrial grade systems are designed to stand up to harsh environments with minimal maintenance. To perform that task, the systems are manufactured using thicker, heavier grade materials than commercial units (i.e. 16-gauge vs 20-gauge cabinets). They are assembled using the highest quality components, such as direct drive TEFC/TEAO motors and solid state electrical components. Further, industrial HVAC systems are required to maintain their dependability even in highly corrosive atmospheres. In the delicate balancing act between efficiency, low cost, and reliability, industrial HVAC systems err on the side of reliability.

If you are new to the world of HVAC, chances are you’ve seen the word “redundant” appear a number of times in product literature. While you might think of redundancy as being something to avoid in writing or speech, it is a critical concept when it comes to HVAC.

In engineering, redundancy is defined as “a part in a machine, system, etc., that has the same function as another part and that exists so that the entire machine, system, etc., will not fail if the main part fails.” In short, redundancy helps to ensure safety-critical systems (such as HVAC) are reliable and continue functioning normally in the event of a component failure.

When planning for a critical HVAC application, it is important to always check with your manufacturer to ensure that the HVAC system you are purchasing is built using inherent redundancy.

What Is a “Heavy Duty” HVAC System?

What Is Inherent Redundancy?

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A part in a machine, system, etc., that has the

same function as another part and that exists

so that the entire machine, system,

etc., will not fail if the main part fails.

redundancy

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When you hear the term “explosion proof” used to classify a product, initially you might think this means the product is able to withstand an exterior explosion. However, according to the National Fire Protection Association (NFPA) National Electric Code (NEC® or NFPA 70), explosion proof refers to a product’s ability to prevent an internal spark or explosion from causing a much larger blast. In other words, a product must be able to contain any explosion originating within its housing and prevent sparks from within its housing from igniting vapors, gases, dust, or fibers in the air surrounding it. Some explosion proof equipment, such as motors and fans, are engineered to be non-sparking according to ANSI/AMCA standards through use of non-ferrous materials and specially designed motors.

This is absolutely critical for HVAC systems that are required to stand up to the rigors and harsh conditions of hazardous environments.

Wall mounted “through-the-wall” style HVAC systems are ideal for buildings on raised platforms or piers because they can be accessed “through the wall” from the inside of the building. This greatly reduces the labor and equipment costs typically associated with servicing an HVAC system mounted on the outside of a building, since there is a lesser need to deploy scaffolding or man lifts.

Purge and pressurization systems are designed to ensure compliance with National Fire Protection Association (NFPA) standards listed in NFPA 496 and the National Electric Code (NFPA Section 70). Essentially, these standards ensure that the atmosphere inside of a building is conducive to allowing equipment to operate effectively. Meeting these standards requires a process known as purging and pressurization, which requires a specifically-designed HVAC system.

Purge and Pressurization HVAC systems are beneficial for wastewater and sewage treatment plants where high levels of methane can impact equipment operations. These systems are also critical in the mining industry, due to the need to control outward pressure.

Severe Duty & Explosion Proof HVAC

Wall Mounted HVAC

Built-in Purge & Pressurization

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LEARN MORE

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What Is a Severe Duty Environment?

A “severe duty” HVAC environment is as challenging as it sounds and it includes some of the world’s most difficult conditions. These conditions include corrosive and hazardous environments, as well as locations with severe temperatures and extreme dirt. Severe duty environments are encountered in nearly every industry in locations across the globe—from a wastewater treatment facility in the cold, high elevations of the Northern Hemisphere to a mining operation in the desert.

Mining contains many of the most potentially hazardous environments in any industry. Extracting resources from the ground creates an extremely dusty environment and, in many cases, the fine powder can collect in areas around buildings and electrical equipment enclosures, causing safety concerns for both personnel and equipment. Having the proper HVAC system is critical to improve corrosion resistance of costly components and ensure safety requirements for surface installations are met.

Wastewater treatment applications contain some of the most corrosive environments on the planet, due primarily to high concentrations of hydrogen sulfide (H2S). Potentially combustible levels of methane can also create an explosion hazard, which results in the requirement of corrosion-resistant, explosion proof HVAC equipment.

Mining

Wastewater Treatment

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LEARN MORE

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Common Hazards & Corrosive ChemicalsSome of the most common corrosive chemicals encountered in a severe duty environment include chlorine, sodium, potash (mined and manufactured salts that contain potassium in water-soluble form), and sulfates. In addition, the list of hazardous chemicals is incredibly extensive.

For example, just in wastewater treatment and collection facilities, the following are chemical and fire/explosion hazards listed in NFPA 820:

Refineries, petrochemical facilities, mines, grain processing facilities, and other applications each have their own hazards covered in other NFPA standards.

If you work in an environment that encounters any of the above hazards or if you are unsure as to whether or not certain chemicals/environments require a specific HVAC system, it is critical to consult your HVAC manufacturer to determine the system that will perform best for your needs.

➡ Alcohol ➡ Chlorine (gas) ➡ Oxygen (combustion aid,

oxidizer) ➡ Diesel fuel, gasoline, and

motor oils

➡ Liquefied petroleum gas ➡ Oxygen generation and

storage ➡ Activated carbon (powdered

or pulverized) ➡ Ozone generation

Some of the most common corrosive chemicals encountered in a severe duty environment include chlorine, sodium, potash, and sulfates.

LEARN MORE

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LEARN MORE

Even the best HVAC systems can benefit from additional protection when they are subjected to the repeated harsh conditions of a severe duty environment. This is why it is important to be aware of the various corrosion resistant coating options available for HVAC systems.

Corrosion Resistant Coil Coatings are applied directly to the most corrosion-sensitive parts of an HVAC system—the coils.

Because the condenser sections of HVAC units remain outside and are therefore constantly exposed to the environment, systems designed for a corrosive atmosphere should include multiple types of protection. Carboline is a coating used in many industries to coat structural steel, fire escapes, water towers, bridges, and oil tanks. As a coating for HVAC units, Carboline provides additional protection to the components in the condenser areas—a section of equipment that is exposed to ambient conditions and would otherwise be unprotected.

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Copper is generally stronger and more durable than aluminum, which can help prevent damage to fins.Copper provides better heat transfer than aluminum (92% vs 49% according to some estimates).Copper is inherently more corrosion resistant than aluminum, since it does not react with water. Instead, it creates copper oxide which can help protect the copper from additional corrosion.

➡ Technicoat ➡ Heresite ➡ E-Coat

➡ Thermoguard ➡ Esgard

Can Corrosion Be Prevented?

Copper Fin/Copper Tube (CuCu) Coils

Corrosion ResistantCoil Coatings

Condenser Protection

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HVAC and the Internet of Things

If you’re unfamiliar with the term, “Internet of Things,” HVAC is the perfect context in which to learn what exactly it is and how it works.

Essentially, the Internet of Things (or IoT) is a network where physical objects (things) are embedded with sensors that enable gathering and leveraging of data with the end goal of automating processes and actions. Cloud-based applications (such as Wi-Fi) are essential to the IoT, as they are the platform where sensor readings are transformed into action.

A familiar example you are likely already aware of is the smart thermostat. These thermostats are equipped with sensors and Wi-Fi capability, both of which enable the user to adjust the temperature of a space remotely from a computer, tablet, or smart phone. This results in automation of processes, increased energy savings, and peace of mind for the user.

This same concept applies to the world of HVAC. By installing web-enabled sensors inside HVAC units, the user has the ability to monitor the functionality of the system in real time and remotely perform actions such as alarm diagnostics and starting/stopping the equipment. Due to the fact that many HVAC units are installed in remote (or multiple) locations, the ability to perform remote diagnostics of alarms can be essential. This can reduce downtime, minimize expensive on-site service trips, and ultimately automate operation sequences.

The Internet of Things is a rapidly expanding network that holds exciting implications for owners and operators of complex HVAC systems. Follow the link below to learn more about the control systems that are available to bring your HVAC system into the IoT and the next generation of smart technology.

The Internet of Things is a network where physical objects are embedded with sensors

that enable gathering and leveraging of data with the end goal of automating

processes and actions.LEARN MORE

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FOUR THINGS You Need to Know When Choosing an HVAC System

Required cooling load is determined by the size of the area to be conditioned. This includes the total interior volume, number of occupants, total heat contribution of all electrical equipment contained in the area, R/U-values of wall, floor, and ceiling insulation system, as well as the final geographical destination of the unit or building.

Depending on the types of hazardous materials encountered in the application environment and their likelihood of being in the atmosphere, your HVAC system may require gas alarms, chemical filtration, a purge and pressurization system, stack packages, and various explosion proof/spark proof application features dictated by the particular area classification.

From salt water to sulfur compounds, corrosive agents are abundant in many industrial and petrochemical facilities. Knowing the types of corrosion likely to occur in your application is helpful in determining the cabinet material (i.e. galvanized steel, stainless steel, or aluminum), filtration (HEPA, chemical, etc.), and coil and copper coatings best suited to your application.

Required Cooling Load

Hazardous Location

Likelihood of Corrosive Agents in the Environment

Different applications require different unit configurations, all of which should be reviewed prior to choosing an HVAC system. These include vertical wall-mounted (packaged to/through-the-wall), roof mounted, pad mounted, or split system configurations, which are often useful in buildings where wall space is limited.

Unit Configuration

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