Daikin VRV, Controls, And Lighting Retrofit Gives St .

Daikin VRV, controls, and lighting retrofitgives St. Louis area high school new lifeThe ChallengesThe original 1957 winghad no existing coolingsystem and structurallimitations that leftprecious little availablespace for ductwork andpiping. The 1964 wing hadan obsolete chilled watercooling system thatneeded to be demolishedand replaced.Daikin’s SolutionThe Daikin VRV systemprovided the school withenergy efficiency equal toor greater than ageothermal system, with asignificant reduction innoise levels previouslygenerated in theclassrooms.While embracing VRV technology,officials at the Bayless HighSchool District insisted that theexisting unit ventilators beretained as backup. However,even during the coldest winter inthree decades, the backup hasnever been called upon.of general and specializedclassrooms, library, auditorium,kitchen/cafeteria, administrationoffices, and a gymnasium. Theoriginal building and gym werebuilt in 1957, with additions in1957, 1964, and 1998.District officials engaged the officeof Facility Solutions Group (FSG)Located in Affton, Missouri, thein nearby Fenton, to help realizeaward-winning Bayless Schoolthe following modernization goals:District serves over 1,500enhancing the learningstudents in suburban St. Louis.The district’s eponymously named environment, improving thehigh school, while small, is noted interior aesthetics, and boostingenergy efficiency. FSG is afor its sports teams and highlyleading provider of mechanical,successful graduating classes.electrical, lighting, and energyIn the summer of 2008 when the services focused on K-12district sought to upgrade Bayless educational facilities.High School as part of a longFor years most of the building wasrange facility improvement plan,HVAC and lighting modernization served by electric resistance heat,which according towere top priorities. With over110,000 square feet spread over Superintendent, Maureen Clancythree stories, the facility consists May, had resulted in escalatingApplication:CommercialLocation:Affton, MissouriWith over 110,000 square feet spread over three stories, the facility consistsof general and specialized classrooms, library, auditorium, kitchen/cafeteria,administration offices, and a gymnasium.

heating bills. FSG engineerswere forced to deal with twounique retrofit scenarios withinthe building: First, the original1957 wing had no existingcooling system and structurallimitations that left precious littleavailable space for ductwork andpiping. Second, the 1964 winghad an obsolete chilled watercooling system that needed to bedemolished and replaced.According to Jeff Lowe, Principalwith FSG, the building’sstructural characteristics mademost traditional HVAC systemoptions unaffordable due toexcessive constructability costs.A water source heat pump(WSHP) system was considered,but would have requiredremoving all of the existingpiping.AN OPTION NEW TO THEREGIONHowever, a Variable RefrigerantVolume (VRV) system was asuperb option for this applicationfor a multitude of reasons. Onekey benefit was that since theVRV condensing units arerelatively light compared totraditional roof top units, theycould be placed on the roofwithout compromising the roofstructure. Additionally, theelimination of chillers and boilerswould free up space in themechanical room.“Given the physical and fiscalrestraints of the project, our teamdetermined that a VRV system inconjunction with a dedicatedventilation system representedthe best life cycle choice,”explained Lowe. Using the FSGdirected design-build projectdelivery approach, the job wasdesigned, bid, and undercontract within 60 days, with theDaikin VRV III system a keycomponent of the effort.Since this was the firstcommercial VRV System of itssize installed in the St. Louisarea, both designers andcontractors faced a steeplearning curve. Lowe explainedthat Daikin’s extensive portfolioof successful commercialinstallations and the company’ssupport system convinced theteam that any potential obstaclescould be quickly conquered.The Daikin VRV system providedthe school with energy efficiencyequal to or greater than ageothermal system, with asignificant reduction in noiselevels previously generated inthe classrooms. The Daikin fancoil units only emit between 3035 dba at full operation, andLowe explained that thiscapability was important to theschool staff.According to Dave Rich, the localDaikin manufacturer’srepresentative with ThermalMechanics, Inc., another reasonDaikin was selected over WSHPwas that the compressors forthose units would have beenlocated throughout the building’scorridors, creating a significantmaintenance challenge.“Given the physical andfiscal restraints of theproject, our teamdetermined that a VRVsystem in conjunctionwith a dedicatedventilation systemOne key benefit is the Daikin VRV condensing units are relativelylightweight compared to traditional roof top units, they could be placedon the roof without compromising the roof structure.represented the best lifecycle choice”Jeff Lowe, Principal withFSG

INSTALLATION ANDMAINTENANCEADVANTAGESRich said that ease ofinstallation was another keyselling point for Daikin’s VRVsystem. Since a VRV systemallows for the installation ofsmall diameter refrigerant linesand requires little to no ductwork– unlike large forced air ducts –the installation was easier andless expensive than otheroptions. “They really liked thefact that the building couldremain operational during theinstallation, that the systemwould be better maintenancewise, and that there would be nowater in the system. Those wereall pluses,” Rich said.Sheet Metal Contractors Inc., afamily-owned HVAC contractoroffering architectural sheet metalservices as well as geothermaland heat pump union work oncommercial, industrial, andresidential jobs, was hired tohandle the HVAC installation.Located in nearby DeSoto, thefirm was also new to VRVtechnology, so its lead for theproject’s installation team, TomPilliard, traveled to Daikin AC’straining center in Carrollton,Texas.“The training in Texas wasinvaluable,” Pilliard said. “PatSankolewicz, Daikin’s areaservice tech, was very helpful inthe process. He also cameonsite to assist with thecommissioning,” he added. Aftercompletion of the Baylessproject, Pilliard also attendedadvanced service training inCalifornia. He highlyrecommended both trainingsessions.BEATING THE BELLIn order to meet the scheduledHVAC completion of mid-August2008, it was necessary to beginconstruction in the spring whileclass was still in session. FSGworked with the districtadministration to rotate a fewclassrooms of students perweek into the library, freeing upthese rooms for the constructionteam.Bayless High School facility director JeffTimeus inspects one of several DaikinVRVIII, four-way ceiling mounted cassettesinstalled throughout the school.SMCI, which has long served asthe school district’s high schooland junior high school HVACmaintenance provider, beganthe installation of the newheating, cooling and ventilationsystems in spring 2008, on avery aggressive constructionschedule.SMCI installed 180 tons ofDaikin VRV equipment, nineheat pump and five heatrecovery condensing units alongwith 81 fan coils, 100 tons ofDaikin McQuay MPS IIpackaged roof top units and 100tons of Addison fresh air units.The project was completed overthe summer break and wasaided by the fact that theexisting system was left intact(piping and unit ventilators)which removed the necessity ofdemolition.The entire system is controlledby the Daikin Intelligent TouchController, which allowsadministrators extensive controlof up to 64 indoor units (doublethat with the addition of anoptional external adapter). TheIntelligent Touch Controller alsoprovides remote interface via theweb for the owner as well as theservicing contractor.While optimistic about thecutting-edge system, schoolofficials did voice concernsabout whether the Daikin systemwould be able to keep thebuilding warm in the harshestwinter conditions. “They had usleave the existing unit ventilatorsto act as backup to the Daikinsystem, but the unit ventilatorshaven’t been needed in thethree winters since the Daikinsystem was installed, includingthe winter of 2009-2010, thecoldest St. Louis winter since1980,” Pilliard said.

Although the VRV installationwas somewhat groundbreakingin the St. Louis area, it served asa regional springboard for thetechnology. The school districtwas so impressed with the DaikinVRV system that it had SMCIinstall a similar system in thejunior high school a year after thehigh school was completed, andit has permitted SMCI toshowcase their facilities.Meanwhile, Thermal Mechanicsand SMCI have honed their VRVexpertise and done several otherDaikin VRV jobs in the area.PASSING WITH HONORSAccording to a detailed study ofthe high school’s utility bills overthe past few years, the energysavings derived from therenovations are substantial: Theold system provided heating tothe entire facility and airconditioning to approximately40% of the building. The newsystem provides 100% heatingand cooling, in addition tomeeting current ventilation codeby utilizing neutral air units toventilate the entire building.However, the most astoundingaspect of the project is that all ofthe heating, cooling and fresh airis delivered with the districtspending less than it had spentoperating the existing system.The old system cost 69,992.24to operate for a year, while thenew system cost 68,761.15.Through more efficientequipment and intelligentcontrols systems, along with atotal building lighting upgrade,Bayless High School was able toadd air conditioning to theremaining 60% of the buildingwhile reducing the annual utilitycost.“That is what I call schoolimprovement,” Pilliard said.On top of the tremendoussavings, the entire building wasready for occupancy with newlights, ceilings, and HVAC for thefirst day of classes in August2008. Superintendent ClancyMay was thrilled with the finishedproduct. “It’s almost as if we’dbuilt a new building. It’sfantastic!”Commenting on the system’sperformance in the particularlycold 2009-2010 winter, Baylessfacility director Jeff Timeus said,“If I hadn’t seen it myself Iwouldn’t have believed it.” As aresult of the full range ofrenovations and improvements,the building was awardedENERGY STAR certification in2011 – an achievement realizedby only a handful of schools inthe region.The VRV heat pumpperformance has been fantasticas well. Through some bitterlycold winters, the VRV heatpumps were able to maintain allheating set points at 0ºF ambientwithout any supplemental electricheat.“It’s almost as if we’dbuilt a new building. It’sfantastic!”Clancy-May,SuperintendentThe VRVIII units pictured here helped provide the high school with energy efficiency equal to or greater than a geothermal system, with asignificant reduction in classroom noise levels.