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the ART of Building HVAC

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 Vol. 56, Number 11

DECEMBER 2019

20 | Transformer
selection and sizing
Selecting and sizing elec-
trical distribution trans-
formers is fundamental for
electrical designers and
engineers

26 | How to correctly size a transformer

8
ON THE COVER: Froedtert & Medical College of Wis-
Engineers must make informed decisions regard-
ing the proper transformer sizing selection, electri-
cal and mechanical requirements and impacts to
consin Center for Advanced Care maximizes efficiency
the electrical system under different operating and
and expandability while simultaneously supporting cut-
loading conditions
ting-edge medicine. Courtesy: Steinkamp Photography

36 | Analyzing NEC 2017 changes

NEWS &BUSINESS Several changes to the 2017 edition of NFPA 70:
National Electrical Code should be noted
5 | Viewpoint
Codes and standards keep the wheels turning
42 | Case study:
7 | Research Energy-efficient
Lighting in office buildings clean rooms
Designers formulated
several energy-saving
BUILDING SOLUTIONS strategies that can be
implemented into the
8 | Advances in building automation HVAC system design of a pharmaceutical-grade
Building automation has seen a tremendous clean room suite
amount of advancement and is changing not only
how buildings are managed and operated, but also
how they interact with the grid ENGINEERING INSIGHTS
51 | New Products for Engineers
14 | Commissioning lighting
occupancy sensors 52 | Lab, research facility design
Installing lighting occupancy sensors and commis- Learn tips on how to design labs and research
sioning the devices have many benefits, including facilities — some of the most high-tech buildings
reducing operational and maintenance costs around

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 NEWS&BUSINESS
VIEWPOINT
CONTENT SPECIALISTS/EDITORIAL
AMARA ROZGUS, Editor-in-Chief/Content Strategy Leader
630-571-4070 x2211, ARozgus@CFEMedia.com
AMANDA PELLICCIONE, Director of Research

Codes and standards

APelliccione@CFEMedia.com
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keep the wheels turning

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EDITORIAL ADVISORY BOARD

JERRY BAUERS, PE, Unlike a hamster wheel, on which the rodent goes
Vice President, NV5, Kansas City, Mo.
MICHAEL CHOW, PE, CEM, CxA, LEED AP BD+C, nowhere, codes and standards can take engineers
Principal, Metro CD Engineering LLC, Columbus, Ohio
TOM DIVINE, PE, anywhere and everywhere
Senior Electrical Engineer, Johnston, LLC, Houston

CORY DUGGIN, PE, LEED AP BD+C, BEMP,
Energy Modeling Wizard, TLC Engineering Solutions,
Brentwood, Tenn.
ROBERT J. GARRA JR., PE, CDT,
Vice President, Electrical Engineer,
CannonDesign, Grand Island, N.Y.
JASON GERKE, PE, LEED AP BD+C, Cx A,
Mechanical Engineer, GRAEF, Milwaukee
JOSHUA D. GREENE, PE,
Associate Principal, Simpson Gumpertz & Heger,
T
he most complex part about
reaching the Consulting-Speci-
fying Engineer audience is that
the brand has to be all things
to all people. Some audience members
want only fire and life safety topics.
Others need all things energy efficien-
specify a system, the building mar-
ket would be flooded with haphaz-
ard designs, inefficient systems and
unsafe products.
And the top articles that have been
published by Consulting-Specifying
Engineer this year include mostly

‘
Waltham, Mass.
RAYMOND GRILL, PE, FSFPE,
cy. Some manag-
Principal, Arup, Washington, D.C. ers want a broad
DANNA JENSEN, PE, LEED AP BD+C, swath of topics to
Codes, standards, guidelines
Principal, Certus, Carrollton, Texas
WILLIAM KOFFEL, PE, FSFPE,
help educate their and regulations truly keep the

’
President, Koffel Associates Inc., Columbia, Md. younger team
WILLIAM KOSIK, PE, CEM, LEED AP BD+C, BEMP, members. wheels of engineering running.
Senior Energy Engineer, Oak Park Ill.
And much like
KENNETH KUTSMEDA, PE, LEED AP, Amara Rozgus, Editor-in-Chief
Engineering Manager, Jacobs, Philadelphia any other medi-
SARA LAPPANO, PE, LC, LEED AP, um, anything
Managing Principal, Integral Group, Washington, D.C.
goes. Print magazines are in high codes- or standards-related articles.
JULIANNE LAUE, PE, LEED AP BD+C, BEMP,
Director of Building Performance, Mortenson, Minneapolis demand. Webcasts and education Best practices, insights on new code
DAVID LOWREY, are a necessity for most profession- versions or “how to specify” with a
Chief Fire Marshal, Boulder (Colo.) Fire Rescue als. Bite-sized lists of topical articles particular code or standard flooded
JASON MAJERUS, PE, CEM, LEED AP,
Principal, DLR Group, Cleveland
and resources, like in a newsletter, are the top 10 articles of 2019.
BRIAN MARTIN, PE, easily digested. The associations that function as
Senior Electrical Technologist, Jacobs, Portland, Ore. What, then, is really the “best” con- code-governing bodies have their
DWAYNE G. MILLER, PE, RCDD, AEE CPQ,
CEO and Co-Founder, UNIFI Labs Inc., Las Vegas
tent? What’s most important for a pro- work cut out for them. Codes typical-
FREDDY PADILLA, PE, ATD,
fessional with 35 years of experience? ly are on a three-year cycle, with sev-
Principal/Senior Electrical Engineer, Page, Austin, Texas What does someone with 10 years in eral revisions, comment periods and
GREGORY QUINN, PE, NCEES, LEED AP, the consulting engineering world need committee discussions held during
Principal, Health Care Market Leader,
Affiliated Engineers Inc., Madison, Wis. to know? The answer is, “It depends.” that time. These organizations should
BRIAN A. RENER, PE, LEED AP, The No. 1 topic requested in be lauded for keeping up-to-date ver-
Principal, Electrical Discipline Leader, SmithGroup, Chicago
all Consulting-Specifying Engineer sions available to engineers, author-
SUNONDO ROY, PE, LEED AP BD+C,
Vice President, CCJM Engineers Ltd., Chicago research studies is codes and stan- ities having jurisdiction and others
RANDY SCHRECENGOST, PE, CEM, dards. Whether we’ve surveyed allied with the building and engineer-
Austin Operations Group Manager/Senior Mechanical
Engineer, Stanley Consultants, Austin, Texas
lighting designers, automation and ing field.
MATT SHORT, PE,
controls experts or mechanical engi- If you’ve been trying to figure out
Project Manager/Mechanical Engineer, neers, the answer never changes. how to jump-start your career for 2020,
Smith Seckman Reid, Houston
Codes, standards, guidelines and get off the hamster wheel. Consider
SAAHIL TUMBER, PE, HBDP, LEED AP,
Senior Associate, Environmental Systems Design, Chicago regulations truly keep the wheels gaining a deeper understanding of codes
MARIO VECCHIARELLO, PE, CEM, GBE, of engineering running. Without and standards, and how they affect
Senior Vice President, CDM Smith Inc., Boston
these playbooks for how to design or building design and construction. cse
RICHARD VEDVIK, PE,
Senior Electrical Engineer and Acoustics Engineer,
IMEG Corp., Rock Island, Ill.
MIKE WALTERS, PE, LEED AP,
Campus Energy Market Leader, MEP Associates, Verona, Wis.
APRIL WOODS, PE, LEED AP BD+C,
Vice President, WSP USA, Orlando, Fla.
JOHN YOON, PE, LEED AP ID+C,
Lead Electrical Engineer, McGuire Engineers Inc., Chicago
www.csemag.com consulting-specifying engineer December 2019 • 5
2020
You drive your accomplishments and dictate your career success, and those achievements
deserve to be recognized. Stand among the past 480 Consulting-Specifying Engineer
40 Under 40 winners who have made their accomplishments known.

To qualify to be a 40 Under 40 winner, nominees must work in the building community,

be 40 years of age or younger (as of May 1, 2020) and be nominated by a supervisor,
academic advisor, peer, mentor, public relations professional, project leader or other
person directly involved in their career progress.

Note: Individuals whose work is related exclusively to single-family housing,

structural engineering or civil engineering are NOT eligible.

40 UNDER 40 PROGRAM AWARDEES WILL:

• Be highlighted in major media arenas as a Consulting-Specifying Engineer
40 Under 40 winner.
• Be offered networking opportunities with other 40 Under 40 awardees.
• Increase the exposure of their company by highlighting projects
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Performance HVAC,
controls specifications
Don't know 5%
Never 1%
Always
11%
39%
44%
Rarely
Frequently
Figure 1: Eighty-three percent of
firms always or frequently write
performance HVAC and controls
specifications, which restricts text
to stating the performance achieve-
ment required. Source: Consulting-
Specifying Engineer 2019 HVAC &
Building Automation Systems Study
$131,000:
Aver-
age total dollar amount of build-
ing automation systems specified
annually for new and existing build-
ings. Source: Consulting-Specifying
Engineer 2019 Lighting & Lighting
Controls Study
64% of engineers report
building owners and contractors
(electrical, HVAC, etc.) as having sig-
nificant impact on fire and life safety
design projects. Source: Consulting-
Specifying Engineer 2019 Fire & Life
Safety Study
42% of engineers are
responsible for selecting the brand
of electrical or power systems
included in specifications. Source:
Consulting-Specifying Engineer
2019 Electrical & Power Study
More research
Consulting-Specifying Engineer
covers several research topics each
year. All reports are available at
www.csemag.com/research.
www.csemag.com
NEWS&BUSINESS
RESEARCH
LIGHTING & LIGHTING CONTROLS STUDY
Lighting in office buildings
T
wo-thirds of engineers spec-
ify, design or make prod-
uct selections for office
buildings, according to the Con-
sulting-Specifying Engineer 2019 Light-
ing & Lighting Controls Study — and
82% of these engineers are responsi-
ble for determining the requirements/
writing the lighting specifications for
these projects. Below are five lighting and
lighting controls findings as they relate to
office building projects:
1. Design value: Engineering firms
are specifying $708,900 annually, on
average, in lighting and lighting con-
trol products for new and existing office
buildings, with 31% specifying more
than $1 million.
2. Specifications: For office build-
ings, performance lighting specifi-
cations are written 73% of the time,
followed by prescriptive (70%) and
open: alternate or substitute (67%).
Top 10 lighting technologies specified
in office buildings
LED
Occupancy sensor
Multilevel lighting or dimming
Daylight harvesting
Building automation
systems (BAS)
Scheduling
Addressable lighting
Plug-load controls
T5, T8 or T12 (any size)
Demand-response lighting
Figure 2: LEDs, occupancy sensors, multilevel lighting or dimming and daylight
harvesting are the most common types of lights, lighting systems or controls
currently being specified into office buildings. Source: Consulting-Specifying
Engineer
consulting-specifying engineer
3. Design coordination: When spec-
ifying lighting for office buildings, the
architect has the most impact on design
(91%), followed by contractors (63%)
and the electrical engineer (58%).
4. Challenges: Inadequate budgets
(62%), the speed of project delivery
(49%) and frequent changes to codes,
regulations and standards (43%) are
the top challenges engineers face when
specifying lighting for office buildings.
5. Design factors: When compar-
ing lighting products for office buildings,
engineers heavily weigh product quality,
energy efficiency, the manufacturer’s rep-
utation and service support offerings. cse
M More
RESEARCH
Access the full 2019 Lighting & Lighting
Controls Study at www.csemag.com/
research. Amanda Pelliccione is the research
director at CFE Media.
92%
92%
71%
65%
46%
52%
45%
38%
35%
34%
December 2019 • 7
BUILDING SOLUTIONS
AUTOMATION AND CONTROLS
By Julianne Laue, PE, LEED AP BD+C, BEMP, BEAP, Mortenson, Minneapolis
Advances in
building automation
Building automation has seen a tremendous amount of advancement and is
changing not only how buildings are managed and operated, but also how
they interact with the grid
T
he original functionality of a build-
ing automation system was to keep a
building climate within a specified
range. With advances in technology,
the BAS can now control temperature,
control building pressurization, regulate humidi-
ty, optimize lighting, monitor performance, indi-
cate device failures, provide access control, control
shading devices and provide alarms in the event of
malfunction. As technology advanc-
L Learning es, the BAS of old is now more
agile and intelligent and capable of
OBJECTIVES managing business success factors
• Understand the core function beyond energy consumption and
and basics of building comfort.
automation systems. Buildings built in 2020 and
• Be able to discuss advanced beyond will be built to building
automation for energy efficiency codes that are up to 50% more effi-
and occupant health and
wellness. cient than when ASHRAE 90.1:
Energy Standard for Buildings
• Appreciate how modern BAS are
business integrators. Except Low-Rise Residential Build-
ings was first issued in 1975; they
• Recognize the relationship
between smart buildings and will operate with computing per-
smart grids. formance that has increased 1 tril-
lionfold since 1956 and they will
have technology that can virtually ensure the No.
1 complaint of building occupants (comfort) will
be nonexistent. New buildings will be smart, con-
nected, healthy and secure. Smart buildings are the
way of the future and without modern BAS, this
would not be feasible.
Modern advances in building automation, dig-
ital technology and the “internet of things” have
made it easy for new and remodeled buildings to
be smart, energy efficient and healthy. It can be dif-
ficult for new and existing buildings to capitalize
on these opportunities as BAS technology is chang-
ing rapidly and requires today’s engineers to under-
stand the basic capabilities and functions of a BAS,
8 • December 2019 consulting-specifying engineer
become technically savvy and incorporate data ana-
lytics into BAS designs and think beyond buildings
to harness possibilities from utility providers.
Functionality upgrades
In the early 1900s, a BAS was simple. If you scour
the internet looking for the beginning of BAS, you’ll
find some great stories of the potential first BAS
installations. All in all, the basics are as simple as a
lightbulb connected to a thermostat. The lightbulb
would turn on when the temperature registered
below a setpoint, signaling workers to shovel more
coal into a boiler. The original intent was to make life
easier for the person operating the building.
Around the 1960s, engineers progressed to
pneumatic controls and in the 21st century to direct
digital and wireless controls. Energy codes, sustain-
ability rating systems and sustainability commit-
ments have increased the demand for better BAS.
Even with need for better systems, the items a
BAS controls have largely remained unchanged. The
core function of the BAS has typically been to con-
trol heating, ventilation and air conditioning equip-
ment to maintain temperature control in buildings.
These traditional systems control heating and cool-
ing plants, air side systems for fresh air delivery and
space temperature and humidity. Many BAS also
can integrate with lighting controls, security and
fire alarm systems, but many times these systems
remain separate. What is controlled and how it is
controlled can largely depend on when the systems
were installed.
Older buildings are limited by the technol-
ogy and design drivers of the age they were built.
Depending on when they were built, the building
may have had control only at the equipment level.
In these buildings, there are controls available that
only control individual pieces of equipment and
they may not be able to be seen by a centralized
www.csemag.com
Figure 1: Froedtert & Medical College of Wis-
consin Center for Advanced Care maximizes
efficiency and expandability while simultane-
ously supporting cutting-edge medicine. Having
integrated and energy-efficient buildings are
a priority. Building automation advancements
and integrations were extensively studied and
incorporated within the facilities to provide
healthy and energy-efficient spaces. Courtesy:
Steinkamp Photography

control system or BAS. Additionally, these build-

ings may have pneumatic or analog controls, which
lack the ability to provide tight control of comfort
conditions.
As older buildings continue to age, their func-
tionality may be unable to meet the needs of a ten-
ant and they can develop problems that are difficult
to solve due to difficulty in acquiring parts. If an
older building does have some level of automation,
it may still have a significant problem in the fact
that an older BAS operates off proprietary proto-
cols making modifications, expansion or integra-
tion into a newer system difficult.
In buildings built during the late 1980s and
beyond, the improvements in central computing
gave way to distributed digital computers (essen-
tially process controllers) located on equipment
(equipment controllers), allowing communica-
tion back to a central system. By 1995, the central
controller began to communicate with the inter- web-based, have graphics that are easy for the user
net, allowing for remote or web-based control of to understand and allow for data analytics and fault
systems. detection.
Also during this period, proprietary protocols
evolved to open protocols such as BACnet. The Current BAS options
incorporation of BACnet into BAS allows for the With the increase in computing performance,
open communication between multiple pieces of advancements in technology and increased demand
equipment on a centralized or head end system. for energy-efficient and healthy buildings, most
By allowing all the communication between indi- new buildings now employ state-of-the-art BAS
vidual pieces of equipment, temperature control is technologies and leverage analytics platforms that
improved, energy efficiency is increased, operating ride on top of the equipment and BAS. These sys-
and maintenance costs are lowered and indoor air tems can perform complex analytics by integrating
quality is improved. At a minimum, the controls are multiple automation systems, metering systems,

Figure 2: This shows the business case for integrated, smart solutions. Smart grids connected to smart buildings to
increase sales, reduce costs and meet sustainability goals. Courtesy: Mortenson

www.csemag.com CONSULTING-SPECIFYING ENGINEER December 2019 • 9

BUILDING SOLUTIONS
AUTOMATION AND CONTROLS
lighting controls, process controls, security, access
control and other app-based smart devices.
The biggest challenge in designing new build-
ings is being educated about new advancements and
being able to scrutinize the different systems avail-
able for clients. New buildings should be designed
as future thinking, with flexibility built in. This
allows for future adoption of new technology and
expandability of systems.
Future of buildings
50% 1 trillion Zero
Reduction in Increase in comput- Occupant
energy consump- ing performance complaints about
tion since 1975 since 1956 comfort
Figure 3: Expec- Energy/cost conservation along with occupant
tations of build- comfort and productivity are two of the largest
ing performance drivers of advancement in modern BAS. By provid-
for the future of ing improved equipment control, real-time moni-
buildings includes toring, trend logging and fault detection building
the integration operators are better equipped to control how the
of smart building buildings are operated, which decreases energy use
automation sys- and increases occupant satisfaction. These systems,
tem technologies coupled with strategic metering and data analytics,
and internet of can further generate success stories around energy,
things integra- carbon or climate goals, as well as wellness goals
tors. Courtesy: (such as air quality or quality of daylighting) that a
Mortenson company may have.
Climate and comfort
Reducing cost or saving money via energy con-
servation is a benefit of an optimized BAS. It is
typically used to help justify the increased costs
associated with a more complex system. However,
there are other reasons for a com-
pany to track energy usage and
reduce consumption. Many com-
panies have strategic goals around
energy conservation, carbon
reduction and/or climate impacts.
To track and validate consump-
tion and conservation it is help-
ful to have automated systems to
perform and track complex cal-
culations. Further, the analytics
provided by an analytics platform
can identify potential areas for
improvement that otherwise may
not have been found.
While wellness and human
comfort can be difficult to track
10 • December 2019 consulting-specifying engineer
and monetize, standards like ASHRAE 55: Thermal
Environmental Conditions for Human Occupan-
cy and ASHRAE 62.1: Ventilation for Acceptable
Indoor Air Quality set a baseline. With the increase
in wellness standards that companies use to attract
and retain employees, it is increasingly important to
be able to verify that occupied buildings are healthy
buildings.
Using a BAS to maintain a healthy building and
trend and verify wellness metrics is common for new
buildings. This is most important in hospital designs.
In an article on BAS in hospitals, Neil Lorenzi writes
“With patient satisfaction and healthy outcomes
more closely tied to reimbursement, hospitals are
seeking ways to improve the overall patient expe-
rience and building performance is critical to that
mission.” High patient satisfaction doesn’t happen
without a state-of-the-art BAS.
Equipment control
By integrating equipment controllers into a
centralized BAS building, operators can optimize
HVAC efficiency and improve control. Examples
of this include using economizers for free cool-
ing, resetting boiler temperature setpoints based on
outdoor air temperature and optimizing building
start/stop times, which allows for night and week-
end setbacks. Occupancy sensors can be integrat-
ed into ventilation systems to optimized ventilation
rates, further reducing energy and improving IAQ,
as well as control lighting. Carbon dioxide and vola-
tile organic compound sensors can further optimize
ventilation rates and occupant health.
By providing improved equipment control and
visualization into system operations, facilities can
see lower maintenance costs and potentially length-
en equipment life. Alarms and trend logs can sig-
nal facility operators before they cause discomfort
to building occupants and escalate into bigger,
more costly problems that could result in equip-
ment failure.
Metering and submetering
Metering and submetering
equipment that uses energy and
integrating the data into a BAS
can provide additional insight into
Figure 4: There are limitations
of pneumatic control systems.
On this 1980s thermostat, the
setpoint temperature is 80°F.
The actual room temperature is
70°F. The current systems can-
not meet the desired setpoints.
Courtesy: Mortenson
www.csemag.com
optimizing a building. To really get into energy con-
servation, the old saying “you can’t manage what
you don’t measure” applies. Typically, metering is
done in two ways — whole building and/or end use.
Whole building metering is helpful when utilities
haven’t provided smart meters. They can measure
whole building use in real-time and in user spec-
ified intervals (each second, minute, 15 minutes,
etc.). End-use meters get into real-time use of ener-
gy on a break-out level such as lighting, fans, water
heaters and plug loads. Many buildings that have Figure 5: This shows
employed end-use meters have used the data to the various building automation
impact tenant behavior through energy conserva- control levels. At the base are individual
tion competitions. equipment controllers. These can be stand alone,
At Mortenson, the competition was on a floor- smart or may need to be connected and controlled by a
by-floor level in the headquarters campus. Every building automation system. The equipment controllers can be
electrical panel on every floor was analyzed and integrated into a functional head end or BAS for building level con-
submetered to most accurately calculate the ener- trol. With strong equipment controls and BAS, an analytics platform
gy consumption on each floor of the building. Each can be used to perform complex data analytics to further optimize
floor was then provided with educational materi- building performance. Courtesy: Mortenson
als similar to the Energy Star Bring Your Green to
Work program.
The end result was a 12.9% reduction in ener-
gy use over a three-month period. All savings were
attributed to the behavioral changed made by the
occupants. An important part of metering and sub-
metering is to understand the purpose of the data
collection before you start to collect it. This avoids
installing equipment and gathering data that you
can’t or won’t use. Information that is accurate and
useful will improve operations, cut costs and pro-
vide the best experience for occupants.
One of the things that happens when data are
gathered and analyzed is that additional data are gen-
erated and one can end up with “paralysis by anal-
ysis.” Harnessing data and generating meaningful
analytics is complicated. Data can be expensive to
acquire and use, and data have little value on their
own. It is only as good as the insight it delivers.
There are companies that specialize in providing
data analytics platforms for buildings. These com-
panies design easy-to-use automation software that
can visualize and analyze real-time information for Figure 6: The example data provided by an analytics platform indi-
multiple applications and can provide metrics on cates the baseline load of the building as well as how the building is
energy, maintenance, productivity and even prod- performing on weekends versus weekdays. Courtesy: Mortenson
uct quality. These systems are intended to integrate
beyond the BAS and can tie into manufacturing,
product quality, financial tracking, etc. Success- control multiple building systems (HVAC, lights,
ful analytics uncover new business insights capable plug loads, elevators, etc.). They use that connec-
of driving real value and greater business perfor- tivity to communicate and automate to generate
mance. Equipment controls and a BAS are just two greater efficiency, security and comfort while sav-
things that an analytics platform can use. ing money. Smart buildings have a modern BAS.
Many smart buildings are designed around the
Smart buildings phenomena of “electrification of everything” and
Smart buildings are those buildings that have transition to 100% renewable energy. These build-
leveraged data and real-time information to opti- ings are better positioned for the future of the elec-
mize energy consumption. They have leveraged IoT trical grid. Incorporation of technologies such as
connectivity, sensors and the cloud to monitor and heat pumps, electric vehicles and other electric

www.csemag.com consulting-specifying engineer December 2019 • 11

BUILDING SOLUTIONS
AUTOMATION AND CONTROLS
Figure 7: The use of submetered data can influence human behavior
to reduce energy consumption, as shown in this example of the com-
pany headquarters floor-by-floor competition. Courtesy: Mortenson
technologies are on the rise and their increased
incorporation could increase U.S. electricity con-
sumption by nearly 40% by midcentury, according
to a National Renewable Energy Laboratory report.
This need to electrify everything has complica-
tions for the electric grid and creates an increased
demand for a smart grid. In a traditional grid scenar-
io energy flows from the utility to the end user. It is a
one-way transmission. A smart grid allows for many
great improvements, but at a baseline one of those
things is the ability to have two-way transmission.
A smart grid is on the utility side of the meter.
It involves the transmission lines, substations and
transformers required to deliver power from the
plant to the users. Smart grids allow for real-time
energy usage and real-time energy pricing and can
help building operators further manage usage cost,
and manage when to use energy and when to gener-
ate on their own through renewable energy. Smart
grids are continually evolving and smart buildings
and BAS need to evolve with it to optimize perfor-
mance on both sides of the meter.
The smart grid will need smart buildings to talk
to for ultimate success. Utilities have committed to
being more connected to their customers, but to be
truly successful, they need their customers to con-
nect to them in a different way. Most of today’s
smart grid integrations end with the utility provid-
ing a smart meter. It is a start, but only a start and
it needs building designs to advance. When a smart
building is connected to a smart grid, there is mutu-
al benefit for both the building owner and power
provider.
What’s next
The Jetsons — the 1960s TV cartoon — family
lived in the future and they had amazing contrap-
tions (smartwatches, video phones, drones, robots,
12 • December 2019 consulting-specifying engineer
autonomous vehicles) that aided in everyday living.
They lived in perfectly climate controlled, healthy
buildings in the sky. We are on the cusp of being
in “the future” portrayed in that cartoon, but The
Jetsons had robots and artificial intelligence. The
automation systems used today continue to rely on
human interaction and interpretation.
As an example, fault detections and alarms still
rely on humans to take action and much of our data
still needs human interpretation. The technology
that limits or eliminates the need for human inter-
pretation is machine learning and artificial intel-
ligence. These technologies are rapidly evolving
and some aspects are being integrated in BAS algo-
rithms, but it is happening gradually.
In today’s increasingly connected world, the
IoT communicates but is not independently intel-
ligent. Current systems typically rely on “after the
fact” reporting: analyze the past, make a change
and hope the test works in the future. If the results
of the change don’t meet expectations a different
change is made and the process is repeated.
In ML and AI, a machine collects the building
management system and analytics platform data
and combines them into increasingly robust data
sets. These data sets are large and contain more
information than a human brain can process. Cur-
rent ML protocols for BMS use the robust data sets
and combine them in a way that allows operators
to schedule equipment based on better data. This
is what is known as a supervised ML system, and
while it is not a fully automated system, it is more
vigorous than the current “after the fact” reporting.
Additional benefits of the ML/AI integration
include: the ability to use multiple data sets to fore-
cast and operate the building off weather predic-
tions, establishing better coordination of complex
systems (combining HVAC, lighting, ventilation
and occupancy) and improved fault detection (opti-
mized continuous commissioning).
In the most succinct terms, the core function
and intent for BAS is to keep humans comfortable,
healthy and safe. The business purpose of the BAS
is to save money and improve productivity. Using
advancements at an equipment level, an automation
level and at an integration level, the BAS is a busi-
ness tool in addition to an energy and comfort tool.
When smart technology is applied to BAS and
those advancements are in sync with smart technol-
ogy from power providers, new business insights
can be uncovered. These insights can drive real
business and environmental value and greater busi-
ness performance. cse
Julianne Laue is director of building performance
at Mortenson. She is a member of the Consulting-
Specifying Engineer editorial advisory board and
was a 2012 40 Under 40 winner.
www.csemag.com
 webcasts
Consulting-Specifying
Engineer webcasts
help you obtain
educational information
on specific topics and
learn about the latest
industry trends.

Check out some of our webcasts on topics like:

• Critical Power
• Electrical Room Design
• HVAC
• Lighting
• Fire & Life Safety
• Industrial Internet of Things

www.csemag.com/webcasts
BUILDING SOLUTIONS
AUTOMATION AND CONTROLS
By Michael Chow, PE, CEM, CxA, LEED AP BD+C, Metro CD Engineering, Columbus, Ohio
Commissioning lighting
occupancy sensors
Installing lighting occupancy sensors and commissioning the devices have
many benefits, including reducing operational and maintenance costs
M
any of us have seen
or personally expe-
rienced a person
frantically waving
their arms in circu-
lar motions when the lighting turns
off in a space controlled by an occu-
pancy sensor. While this may seem
comical at first, users in these spac-
es tend to get frustrated at the occu-
pancy sensor and override it to avoid
being left in the dark. Occupancy
sensors then get a bad rap. Why did
the occupancy sensor fail to keep the lights on?
Lighting uses approximately 20% of the total
energy consumed in commercial buildings, accord-
ing to the U.S. Department of Energy. There is great
potential for energy savings by reducing the lighting
levels or turning the lighting off when not needed.
Occupancy and vacancy sensors are devices that
use sensors to detect when a space is
L Learning unoccupied and accordingly automat-
ically turn off (or dim) the lighting
OBJECTIVES fixtures. This saves energy by turning
• Learn energy codes and the lighting off in a space or room if it
standards related to lighting and is not occupied. The device can turn
occupancy sensors.
the lighting fixtures on automatically
• Understand the commissioning upon detecting the presence of occu-
process for lighting and lighting
pants and thus is referred to as an
controls.
occupancy sensor.
• Know the role of the
Vacancy sensors are like occu-
commissioning authority in the
design of lighting systems. pancy sensors and use similar sen-
sor technology. However, vacancy
sensors require the occupant to turn
the lighting fixtures on in a room or space by press-
ing a manual switch, which typically is integral to
the motion sensor. See Figure 1 for an example of a
wall-mounted vacancy sensor with dual technology
(passive infrared and ultrasonic). The button with
the light bulb is pressed as a manual on to turn on
the lighting fixtures manually.
14 • December 2019 consulting-specifying engineer
Figure 1: An occupancy sensor
with dual technology (passive
infrared and ultrasonic) is shown.
The button with the light bulb
image is pressed as a manual on
or off to control the lighting fix-
tures manually. Courtesy: Metro
CD Engineering
Vacancy sensors should provide
greater energy savings than occu-
pancy sensors because they give the
occupant a choice of whether to turn on the light-
ing fixtures. For example, if there is enough ambient
light in an office with windows for daylight entering
through the windows, the occupant may choose not to
turn on the lights at all. Conversely, with an occupancy
sensor, the lighting fixtures will turn on automatically
regardless of how much daylight is in the room.
This article will use the term “occupancy sen-
sors,” which can be either occupancy or vacan-
cy sensors depending upon the owner’s project
requirements.
Studies have shown that adding occupancy light-
ing controls can reduce lighting energy use 10% to
90% or more, depending on the use of the space in
which the sensors are installed, according to the
U.S. Department of Energy (see Table 1).
One study conducted by the U.S. Department of
Energy on a university campus found that install-
ing wired occupancy sensors to control lighting in
more than 200 rooms in 10 buildings provided an
annual cost savings of about $14,000 with a simple
payback of 4.2 years.
Occupancy sensors are also mandated by ener-
gy codes. ASHRAE Standard 90.1-2010 and 2013:
Energy Standard for Buildings Except Low-Rise
Residential Buildings requires that lighting auto-
matically turn off or be reduced in output in spaces/
areas such as conference rooms, classrooms, break-
www.csemag.com
‘ Lighting uses approximately 20%
of the total energy consumed in
commercial buildings, according to

’
the U.S. Department of Energy.

rooms, storage rooms, private offices, etc., with a

30-minute maximum timeout setting, both for new
construction and for major retrofits. Occupancy
sensors help achieve this requirement.
It is important to understand occupancy sensors
need to be commissioned to realize these savings
in practice.

Commissioning guidelines
How does an engineer or commissioning agent
commission occupancy sensors lighting controls?
Fortunately, there are guidelines and processes:
ASHRAE Guideline 0-2019: The Commissioning
Process and ASHRAE Standard 202-2018: Commis-
sioning Process for Buildings and Systems; the ACG
(AABC Commissioning Group) Commissioning
Guideline; and IES DG-29-11: The Commissioning
Process Applied to Lighting and Control Systems.
The IES Lighting Handbook defines commis-
sioning of lighting systems as “a systematic process
that ensures that all elements of the lighting con-
trol system perform interactively and continuous- Figure 2: Ohio Northern University’s James Lehr Kennedy Engineer-
ly according to documented design intent and the ing Building has increased laboratory space and an abundance of
needs of the building owner.” natural daylight in the building. Courtesy: Tara Grove, Metro CD
Energy codes and U.S. Green Building Coun- Engineering
cil LEED certification have made commissioning
of lighting controls a requirement. Standard 90.1
requires functional testing of lighting controls and Table 1: Occupancy sensor savings
systems. Room type Occupancy sensory lighting energy savings
IES DG-29-11 breaks down the commission-
Breakroom 29%
ing of lighting control systems into the following
phases: Classroom 40% to 46%
Conference room 45%
• Pre-design. Corridor 30% to 80%
• Design. Office, open 10%
• Construction.
Office, private 13% to 50%
• Occupancy and operations.
Restroom 30% to 90%

The pre-design phase is when the commission-
ing team is formed and is led by the commission-
ing authority. The commissioning team, consisting
of the construction manager, subcontractors and
lighting engineer/designer, creates the commission-
ing plan, develops the owner’s project requirements
and provides procedures to identify and track issues
during the commissioning process.
The OPR should include performance require-
ments for lighting control systems. For example, a
section of the OPR for occupancy sensors may state:
Storage area 45% to 80%
Warehouse 35% to 54%
Table 1: The table shows typical savings by room type when using
occupancy sensors. Courtesy: U.S. Department of Energy
• Occupancy sensors shall be used to turn off
lighting when a space/area is unoccupied. The
sensors should be set for a maximum 30-min-
ute timeout to shut off lighting.

www.csemag.com consulting-specifying engineer December 2019 • 15

BUILDING SOLUTIONS
AUTOMATION AND CONTROLS
• Occupancy sensors shall use vacancy mode
to turn lighting on in enclosed private offices
with automatic off.
• Occupancy sensors shall integrate with the
heating, ventilation and air conditioning sys-
tem and the building automation system in
private offices to turn off lighting when unoc-
cupied and provide code minimum ventila-
tion levels.
• Daylighting harvest sensors shall be installed
in all open office areas. Daylighting controls
shall dim the lighting automatically to main-
tain a minimum of 30 foot-candles measured
at the desktop height above finished floor.
In the design phase, the design engineer should
complete the basis of design that explains the con-
cepts that the engineer will employ to achieve the
performance requirements of the OPR. For exam-
ple, suppose the OPR states: “Vacancy sensors shall
be used in all enclosed private offices.”
Figure 3: The 105,000-square-foot, $30 million, three-story James
Lehr Kennedy Engineering Building at Ohio Northern University,
Ada, Ohio, was completed in fall 2019. The new facility in allows
more engineering student enrollment, increases laboratory space
and encourages student-faculty collaboration. Courtesy: Tara Grove,
Metro CD Engineering
16 • December 2019 CONSULTING-SPECIFYING ENGINEER
A BOD to achieve this OPR may state: “Vacan-
cy sensors using passive infrared and ultrason-
ic, self-adaptive technologies shall be used in all
private enclosed office. Sensors shall turn the
lighting off within five minutes after an office is
unoccupied.”
Typically, the contractual design phases of a
project consist of schematic design, design devel-
opment, construction documentation, construc-
tion administration and final punch list.
The schematic design contains an outline of
the lighting control system to fulfill the OPR. The
design development phase includes detailed draw-
ings and specifications.
The construction documentation incorporates
commissioning in the specifications. It is high-
ly recommended that the commissioning specifi-
cations be incorporated no later than the design
development phase. The specifications would be
updated in the construction documents phase.
The specifications include lighting controls
to be tested and roles and responsibilities of the
commissioning authority and the contractor(s).
Including these items helps reduce or even elim-
inate conflicts and issues during commissioning
tasks such as functional testing. For example, a
commissioning specification may state, “The con-
tractor shall notify the commissioning agent in
writing at least 14 days in advance of all pre-func-
tional testing.”
The commissioning authority reviews the light-
ing control design documents to check compli-
ance with the OPR and the commissioning plan.
For example, the commissioning authority may
check that occupancy sensors are located correctly
in each space/area. Another example includes ver-
ification that occupancy sensors are located more
than 6 to 8 feet from HVAC diffusers (especially
for sensors that use microphonics).
Here are some typical occupancy sensor design
items that should be reviewed by the commission-
ing authority:
• Occupancy sensors are not allowed to control
lighting fixtures in electrical rooms as stated
in the NFPA 70: National Electrical Code.\
• Time delay setting of occupancy sensors stat-
ed in the specifications shall match the OPR.
How long should the lighting fixtures stay
on once no motion is detected? The less time
the lighting fixtures stay on, the higher the
savings will be. The commissioning author-
ity should discuss this with the owner and the
design team. With LED lighting now the stan-
dard and with frequent switching of LED light-
ing fixtures having little effect on the longevity
of LED light sources, time delay settings should
www.csemag.com
CASE STUDY: University lighting system commissioned

O
hio Northern University’s 105,000-square-foot, to the door and can result in the lighting in her office
$30 million, three-story James Lehr Kenne- to turn on when people walk past the door, but do not
dy Engineering Building was completed in fall enter the office.
2019. The new facility in Ada, Ohio, allows more engi- The incorrect location of the occupancy sensor has
neering student enrollment, increases laboratory space resulted in the lighting in the room to turn off while the
and encourages student-faculty collaboration. Student occupant is completing tasks at her desk. The occupant
input resulted in an abundance of natural daylight in the has tried waving her arms, but the lighting remained off.
new building. The facility has daylighting harvest sensors, The sensor’s self-adapting technology usually recalibrates
vacancy sensors and high-effica- the sensitivity of the sensor when

‘
cy LED lighting. The building
is seeking U.S. Green Building
Council LEED-NC v3 certification.
The commissioning of the
occupancy sensors was done
post-occupancy to allow the
occupancy sensors with self-
adapting technology to adjust to
the use of the building. This usu-
ally takes about a week for the
sensors to automatically adjust
it detects someone waving their
The commissioning arms, but in this case, since her
seated position was not with-
authority needs to in the sensor’s minor movement
coverage, the sensor could not
ensure the design keep the lights on.
intent of the occupancy The occupancy sensor is being
relocated where shown on Fig-
sensors is met during ure 4 and this should fix the issue
the commissioning of the lights turning off when the
occupant is working at her desk.

’
to the use of the rooms and process. It is critical that the design
spaces. engineer show the occupancy
The commissioning authority sensors in the correct location.
found issues with some of the installed occupancy sen- Most sensor manufacturers will provide no-cost evalua-
sors. These ceiling-mounted sensors were not installed tions of an engineer’s design to ensure major and minor
where there are shown on the construction drawings. coverage motions are correct. The installing contractor
This led to sensors not performing as designed and should be instructed before construction to ensure the
resulted in the room occupants “waving their arms” to sensors are installed where shown on the construction
keep the artificial lighting on. drawings to eliminate sensor issues. The commissioning
Figure 4 shows a private office, Room 109D, with authority needs to ensure the design intent of the occu-
the ceiling-mounted occupancy sensor labeled “OS3” pancy sensors is met during the commissioning process.
in the room. The sensor
is placed too far away
from the desk to detect
minor motion such as
the occupant using a
computer while seated
at her desk. The sensor
also is placed too close

Figure 4: A partial
first-floor lighting plan
showing the case study
private office with
design location of occu-
pancy sensor and actual
installed location of sen-
sor. Courtesy: Metro CD
Engineering

www.csemag.com consulting-specifying engineer December 2019 • 17

ARCHITECTU RAL
LED EDGE-LIT
EXIT COMBO
Fully adjustable 2.5W LED lamps
Up to 54’ on-center spacing
Architectural low-profile design
Surface & recessed configurations
Includes single- & double-face panels
Optional remote capability
BUILDING SOLUTIONS
AUTOMATION AND CONTROLS
be 15 minutes or less. National Electrical Manufactur-
ers Association guidelines recommend a 15-minute time
delay. However, you may want to start with a 10-minute
delay for greater energy savings and adjust to a longer time
delay if occupants request it (refer to the U.S. Department
of Energy).
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– Sensors should not be installed within 5 feet of HVAC sup-
ply diffusers.
– For enclosed spaces, locate a wall-mounted sensor where it
will not be blocked when the door is open.
– Do not install sensors on an angled or inclined ceiling as
they typically do not perform well when positioned at an
angle.
– Verify that the type of sensor used will sense both minor
and major movement.
– Restrooms should typically use ceiling-mounted ultrason-
ic sensors to detect movements in the stalls. Many lighting
engineers/designers may use just one wall sensor to detect
movement when an occupant enters a restroom, but this
sensor may not detect an occupant in a restroom stall. It
is good practice to have adequate lighting in restrooms in
an unoccupied mode should the lighting be turned off at
inappropriate times.
– Ceiling height should be considered when placing a sensor.
Most sensors should not be installed with ceiling heights
over 15 feet.
The commissioning authority always notifies the design team
of issues discovered during the review of the documents. The
design team should then reply formally to the commissioning
authority’s comments and resolve all issues.
The construction administration phase involves training of
the facility personnel on the operation and maintenance of the
lighting and control system. A good example of a training pro-
gram includes explanation on how occupancy sensors can be
modified (e.g., change from occupancy to vacancy mode).
Also included in this phase is performance testing. For light-
ing control systems, the commissioning authority, electrical
contractor, operators, manufacturer representatives and other
stakeholders are typically present for the testing. A sample par-
tial performance test for occupancy sensors may include verifi-
cation that the lighting fixtures in a space turn on within 3 feet of
entering a space in a private office.
The commissioning authority maintains an issues log that
begins at the pre-design phase. The log includes details of each
issue and who is responsible to resolve each issue one.
A systems manual, with specified sections provided by the
construction manager, is handed by the commissioning team
to the owner at the project turnover. The systems manual pro-
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input #5 at www.csemag.com/information 18  December 2019 CONSULTING-SPECIFYING ENGINEER
ation and maintenance of the lighting controls. Also
included are record drawings, submittals (shop draw-
ings), the issues log, the OPR and BOD, as well as
operations and maintenance manuals. Training
should always include a review of the systems man-
ual and its use in normal operation of the building.
The occupancy and operations phase begin at
substantial completion. This includes providing
completion of any deferred testing and training as
well as maintaining the systems manual.
The commissioning requirements of Standard
90.1-2010 require that the construction documents
identify who will conduct and certify the testing.
All specified lighting controls and associated soft-
ware must be calibrated, adjusted, programmed and
assured to operate in accordance with construction
documents and manufacturer installation instruc-
tions. Specific requirements are identified for occu-
pancy sensors, programmable schedule controls and
photosensors.
For example, at a minimum, the party conducting
the testing must confirm that the placement, sensi-
tivity and timeout settings for any installed occupan-
cy sensors provide acceptable performance — for
example, the lights must turn off only after the space
is vacated and must turn on only when the space is
occupied. Time switches and programmable sched-
Small Devices,
Big Impact.
CESIM. Small Devices, Big Impact.
Comfort | )RIVK])JƤGMIRG] | Safety | Installation | Maintenance
input #6 at www.csemag.com/information
ule controls must be programmed to turn the lights
off. And photocontrol systems must reduce light lev-
els produced by the electric lighting based on the
amount of usable daylight in the space as specified.
Standard 90.1-2010 requires a commissioning
authority be engaged that is not involved in the design
or construction team. The commissioning authori-
ty verifies that the lighting controls are adjusted, pro-
grammed and functioning in accordance with the
design and the manufacturer’s installation instruc-
tions. The commissioning authority then submits doc-
umentation certifying that the lighting systems are in
compliance with or exceed the performance require-
ments outlined for the project in the OPR.
Installing occupancy sensors and commissioning
the devices have many benefits, including reducing
operational and maintenance costs. And with prop-
erly designed and commissioned occupancy sensors,
it’s time to say goodbye to days of people frantically
waving their arms when the lights turn off. cse
Michael Chow is the founder and president of Metro
CD Engineering. He holds a BSEE from Ohio North-
ern University and is the current chair of the univer-
sity’s engineering advisory board. He is a member of
the Consulting-Specifying Engineer editorial advi-
sory board and is a 2009 40 Under 40 winner.
Installation in a Snap
Belimo offers a complete range of sensors
designed with a snap-on cover, enabling easy
installation while providing NEMA 4X/IP65
protection.
 By Robert Sander and Mario Caraveo, NV5, Las Vegas
Transformer
selection and sizing
Selecting and sizing electrical distribution transformers is fundamental
for electrical designers and engineers
I
n the United States, transformers are gov-
erned by the NFPA 70: National Electrical
Code; in this case, the latest version of the
code published in 2017 will be used. Trans-
formers are fundamental components in
many different commercial, industrial and res-
idential electrical systems. They allow for the
working voltage to either be “stepped” up or down.
Transformers are able “step” voltage
L Learning up or down by using the magnetic
field produced passively by the cur-
OBJECTIVES rent carrying windings.
• Learn design concepts for The most basic version this con-
selecting and sizing electrical cept can be illustrated by two cop-
transformers.
per loops of different size, one inside
• Review the codes and of the other with no contact. If one
considerations associated with
transformer design. of these loops has current passing
through, it then an induced voltage
• Evaluate a case study profile to
highlight best practices. is seen at the terminals of the other
loop. The voltage and current in the
second loop is proportional to the
voltage and current associated with the first loop.
The amount of loops or wind-
ings can be changed to create a
variety of voltages to work with.
Transformer windings are
made of aluminum or cop-
per. Aluminum is the com-
mon selection because it is less
expensive while offering simi-
lar electrical characteristics to
copper. Aluminum is lighter in
weight than copper, but is typi-
cally larger in physical size.
Power distribution trans-
former power rating sizes are
standardized throughout the
industry. The most common
type of application within a
commercial facility are three-
20 • December 2019 consulting-specifying engineer
phase delta primary to wye secondary step-down
type transformers. Industry standard sizes for
480- to 120/208-volt wye transformers are com-
monly 15, 30, 45, 75, 112.5, 225, 300 and 500
kilovolt-amperes.
There are also single-phase 277-or 480-volt
transformer sizes available at 5, 7.5, 10, 15, 25,
37.5, 50, 75 and 100 kilovolt-amperes. This is not
a comprehensive list, but illustrates the variety and
range that is commercially available.
In general, three-phase transformers are the
most commonly used for electrical designer appli-
cation and selection. Single-phase transformers
tend to be used for special applications or voltages.
An example may be unit equipment that specifical-
ly requires 240 volts single-phase where the service
voltage is 120/208 volts wye three-phase. For a spe-
cial case like this, it is common to only provide a
single-phase transformer for the equipment because
there won’t be a multitude of loads served by it.
When a single-phase transformer is used for gener-
al distribution, it can cause phase imbalances when
using a three-phase utility. Oth-
erwise, if a property is served by
single-phase and a transformer
is used (e.g., for isolation) then a
single-phase transformer would
be appropriate.
All transformers are required
to have a nameplate with the
Figure 1: This harmonic miti-
gating transformer does not
have vibration-isolation pads.
Typically, these are noted dur-
ing inspection by authorities
having jurisdiction or field
observations by engineer.
Courtesy: NV5
www.csemag.com
information described in NEC 450.11(A)(1-8).
This information includes the name of manufac-
turer, rated kilovolt-amperes, frequency, primary
and secondary voltages, impedance of transform-
ers 25 kilovolt-amperes or larger, required clear-
ances for transformers with ventilating openings,
amount and kind of insulating liquid where used.
For dry-type transformers, temperature class for
the insulat ion system.

Transformer sizing
The first step to sizing a transformer is to deter-
mine the load that will be served, either at the branch
circuit, feeder or service level. This starts with esti-
mating or calculating the demand load using
NEC Article 220 and then applying and applicable
demand factors. Based on the types of loads served,
demand factors will reduce the calculated load to
determine appropriate sizing of the transformer. ‘
This calculated design load represents the base
load or starting point for transformer sizing. Once
you have determined the base load, depending
on the type of project, a few considerations will
need to be made when determining the final size
of the transformer. These considerations include
the future flexibility, available physical space, cost
and project type.
Future capacity or expansion for a property
is one of the most crucial considerations for siz-
ing. This is important because both an under-
sized and an oversized transformer operate at
lower efficiencies and could cause degrading dam-
age to equipment over time. It is crucial to under-
stand the owner’s intended use for the facility.
There are instances where the property is not like-
ly to expand and as such, owners may not require
capacity for future loads or equipment.
However, some owners may not use their
space to full capacity at project completion (e.g.,
a pharmaceutical lab filled to half occupancy) and
it would be prudent to allow capacity for future
expansion at the transformer. Such considerations
for expandability should be discussed and coordi-
nated by the design consultant with ownership to
suit their needs.
Additionally, depending on the project type
(e.g., new construction, tenant improvement,
remodel) there may not be physical space for
expansion. The addition of a transformer to an
existing property can be costly dependent on loca-
tion and size. The location of an added transform-
er requires coordination for ventilation, spacing
for code-required clearances and may require
structural bracing. Furthermore, transformers
produce excess heat that the mechanical engineer
must evaluate existing systems to determine if they
will support sufficient cooling.
Another consideration is the weight; some
smaller transformers weigh less than 1,000 pounds
Figure 2: A sample nameplate from a 1,500 kilovolt-amperes dry-
type transformer lists all parameters related to the transformer
construction and capabilities. Courtesy: NV5
Figure 3: This is a
sample K-factor
transformer name-
plate. Note that the
K-factor is clearly
identified. Courtesy:
NV5
and can be incorporated with minimal structur-
al coordination. These considerations should be
evaluated before the addition of a transformer to
an existing electrical system. Typically, it is easier,
in terms of cost and coordination, to accommodate
a larger-sized transformer in a new construction
structure, but a remodeling project may prove to be
more costly and require more coordination.
Lastly and important for an owner to consider,
is the transformer’s cost. Usually, the larger the size
of the transformer, the higher the equipment and
installation cost. Often, for larger transformer sizes,
they can also incur additional design and structural
costs. For example, a 225 kilovolt-amperes dry-type
transformer placed at an upper floor and typical-
ly weighs 2,000 to 4,000 pounds and would require
structural engineers and architects to consider the
weight and additional bracing needed to support
the equipment load.
In general, as with most other aspects of elec-
trical engineering, it is best to be conservative and
oversize at the early stages of a project until fur-
ther design development and final determination
is made considering all the preceding items. It is
worth noting that it is easier to downsize a trans-
former later in design, for coordination purposes,

www.csemag.com consulting-specifying engineer December 2019 • 21

 rather than upsize the transformer after the pre-
liminary stages of design.
Information regarding transformer installation
is found in the NEC, Article 450. Article 450.3(A)
and (B) provide tables for maximum rating or set-
ting of overcurrent protection for transformers
with voltages for both, equal to/less than and larger
than 1,000 volts. The numbers given in the tables
are percentages of the transformer-rated current
which is derived by taking the transformer’s kilo-
volt-ampere rating and dividing it by the voltage of
the feeder.
Needless to say, the primary and secondary
feeders of a transformer will have different current
requirements corresponding to their voltage with
one exception — transformers used for power iso-
lation. Primary protection allows an engineer to
make a simpler design, but using a combination of
single and secondary protection allows for greater
flexibility in the use of a transformer’s current rat-
ing. One could use the full rating of a transformer
as long as the feeders are still adequately protected
according to these tables.
Types of transformers
Once a transformer size is determined, consid-
er the application of and types of loads that will be
served by the transformer. In commercial design,
there are a few commonly used types of transformers
with characteristics as described below:
Dry-type transformers use ambient air to cool
the core and windings. These transformers tend to be
larger than liquid-filled transformers, but are gener-
ally less expensive in materials and installation costs.
The two commonly used dry-type transform-
ers are encapsulated and ventilated. Nonventilated
or encapsulated are sealed completely with surface
area cooling, suited for wash-down areas and cor-
rosive, combustible or other harmful conditions.
Ventilated dry-type transformers are made with
openings that allow air to move through the inside,
are larger in dimension, use different insulation
materials and contain an enclosure for the wind-
ings providing physical protection for the equip-
ment and for personnel.
Liquid-insulated transformers use liquid for
cooling and to act as an insulator for the cores.

CASE STUDY: Manufacturing facility electrical design

A
n equipment manufactur-
ing company has procured an
existing building with 277/480-
volt wye service to open a new office
for its business. The company manu-
factures and tests specialized, sensitive
electronic equipment for the health
care industry. It is opening a new loca-
tion for its operations and plans to use
80% of the space and power capacity
with a requirement to allow for at least
20% growth in the next few years.
Project scope consists of standard
commercial office space as well as a
portion of laboratory and manufactur-
ing. The owner’s required power allow-
ances are: 10 volt-amperes per square
feet for office, 25 volt-amperes per
square feet for lab and 20 volt-amperes
per square feet for manufacturing areas.
Upon receiving floor plans, the areas
are 14,000 square feet of office, 8,000
square feet of lab and 120,000 square
feet of manufacturing.
Lastly, all office and lab spaces will
need 120 and 208 volts single-phase
distribution, manufacturing requires
a 70/30 split of 277/480 volts (single-
and three-phase) and 120/208 volts
(single- and three-phase), respectively.
From this information and criteria, the
connected load power allowances are
determined:
• Offices
Of (120/208 volts): 10 volt-
amperes/square feet x 14,000
square feet = 70 kilovolt-amperes
• Laboratory (120/208 volts): 25
volt-amperes/square feet x 8,000
square feet = 96 kilovolt-amperes
• Manufacturing (277/480 volts): 20
volt-amperes/square feet x 120,000
square feet x 0.7 = 1,680 kilovolt-
amperes
• Manufacturing (120/208 volts): 20
volt-amperes/square feet x 120,000
square feet x 0.3 = 720 kilovolt-
amperes
The next stage is to select trans-
former capacity sizes. Office spaces can
be served from a 75 kilovolt-amperes
transformer based on the next standard
size of transformer and the calculated
connected load. However, the owner’s
requirements are to account for at
least 20% growth for future. Once the
growth amount of 1.2 for the office
space is factored in, we arrive at 84
kilovolt-amperes. This connected load
will need to be serviced by the next
standard size, 112.5 kilovolt-amperes.
The laboratory space requires
115.2 kilovolt-amperes (with the 20%
growth included) and will require a 225
kilovolt-amperes transformer. Manu-
facturing will similarly require a 1,000
kilovolt-amperes transformer to service
its 864 kilovolt-amperes (with growth
accounted) connected load at 120/208
volt distribution.
Now that loads are accounted for,
general locations in the building can
be considered. There are many means
and methods to determine appropriate
transformer locations and distribution,
so one design philosophy described
here. The building layout is rectangular.

22 • December 2019 consulting-specifying engineer www.csemag.com

Mineral oil and bio-based oils are the most com-
monly used liquids. Liquid-insulated transformers
allow better cooling that translates to a more com-
pact transformer than a dry type.
However, these transformers require period-
‘ Once a transformer size is determined,
consider the application of and types of
ic oil analysis, but are considered less costly for loads that will be served by the transformer.
repairs. Bio-based oils are less flammable and are
environmentally friendly in the case of a leak. In commercial design, there are a few

Less flammable is considered for liquids with a
fire point of not less than 300°C. Exterior pad-
mounted utility transformers are typically used
with mineral oil and are considered combustible.
For transformers less than 35 kilovolts, indoor
installations may require minimal requirements
such as an automatic sprinkler system or liquid
containment area with no combustibles stored
inside the room.
NEC 450.23 covers the requirements for
indoor and outdoor installations for these liq-
uid-insulated types. Additionally, nonflammable
fluid-insulated transformers that use a dielectric
fluid that is nonflammable require a transform-
er vault to be installed indoors per NEC 450.24.
’
commonly used types of transformers.
Oil-insulated transformers must be installed in a
transformer vault per NEC 450.26 when indoors.
Special applications
K-rated and harmonic mitigating transform-
ers typically are used for harmonic, nonlinear
loads such as computer/servers with switch-mode
power supplies, gaming slot machines, LED light-
ing, motors or variable frequency drives. HMTs can
be used to correct the harmonic issues generated by
the nonlinear loads.

Overall dimensions are 200 feet wide
by 655 feet long, with a second story at
the building front that will house offices
and laboratory spaces.
Because the labs and offices reside
in the same area, consolidation of the
lab and office loads to one transformer
are considered. This will give a com-
bined connected load of 166 kilovolt-
amperes that can be serviced by a 225
kilovolt-amperes transformer.
One larger combined transformer
allows for space and cost savings.
Instead of two rooms at either side of
the building with associated feeders,
the single larger transformer can be
centrally located. In this scenario, with
the labs and offices on two floors that
are relatively small, the transformer is
placed at grade level to avoid potential
structural impacts.
Distribution for the manufacturing
floor requires additional consideration.
With the 120/208 volt demand spread
throughout the floor space, transform-
ers must be arranged to avoid exces-
sive voltage drop. With a 600-foot-long
Figure 4: In contrast to harmonic miti-
gating transformer without vibration-
isolation pads, dry-type transformers
are shown with pads. Courtesy: NV5
run and assuming somewhat uniform
distribution, two locations are planned
— one at 200 feet down and another at
400 feet. This will cover the manufac-
turing floor and will allow the load to
be split for the manufacturing area to
360 kilovolt-amperes, allowing two 500
kilovolt-amperes transformers to service
either end of the manufacturing area.
These loads are only rough esti-
mates, but allow the design team to
prepare and allocate floor space. Once
demand factors (if any) are applied,
the sizes may be revisited and sized
accordingly.
Lastly, the specification of the trans-
formers is considered. Because this is
an indoor and controlled environment,
dry-type ventilated transformers will
be used. To reduce cost, the windings
for the transformers will be aluminum
instead of copper. At the office and
labs, harmonic mitigating transform-
ers are considered due to the sensitive
nature of the equipment in the facility.
This selection also will help increase
power quality and reduce inefficiencies,
in the form of harmonics, introduced
from the multitude of AC/DC power
supply transformers common to mod-
ern computers and electronics.

www.csemag.com consulting-specifying engineer December 2019 • 23

‘
Dry-type transformers installed indoors
require at least 12 inches of separation
heat in the transformer coils. HMTs suppress or
reduce the effects of these odd harmonics, in par-
ticular the third harmonic that is additive on the
neutral conductor.
from combustible material for transformers Transformer design considerations
rated less than 112.5 kilovolt-amperes, Location: An important factor to consider is
physical location of the transformer. The type of

’
per NEC 450.21(A). environment/building material where the trans-
former is located and the surrounding occupan-
cies or rooms adjacent to the transformer should
K-rated transformers, on the other hand, do not be considered.
mitigate harmonics, but rather allow for a more For example, an oil-insulated transformer
robust system to tolerate the harmonics. Transform- installed indoors requires spill containment areas
er failure from harmonics are caused by excessive that are typically more costly. Specifically, for oil-
and/or constant overheating of the coils leading to a insulated transformers, a vault room would be
faster degradation of the coils’ insulation. Electrical required by NEC Article 450.26, unless at least
systems with excessive harmonics can cause elec- one of six exceptions are met. There are advantag-
tronic components to fail due to a distorted sinu- es and disadvantages for using a transformer vault
soidal wave. depending on any number of variables, however
The major difference between K-rated trans- they require special attention and tend to add sig-
formers and HMTs is that K-rated transformers are nificant cost, which should be taken into consider-
built to handle the stresses and strain of nonlinear ation. Although they are not governed by the same
loads depending on the level. Meanwhile, HMTs building construction regulations mandated by the
are physically constructed in such a way to reduce NEC, utility companies commonly use oil-insulat-
or mitigate harmonic currents from downstream ed transformers.
devices to keep disruptive currents from traveling Additionally, when locating a transformer, con-
electrically upstream of the transformer. sider its physical location in the building and the
Most electronic equipment nowadays is pow- area it is intended to serve and distribute power to.
ered by switch mode power supplies. SMSPs con- A 277/480 volt-delta transformer is better suited
vert sinusoidal alternating current to constant for longer runs on medium-sized buildings due to
direct current using rectifiers and capacitors that voltage drop. To avoid sizing larger feeders for lon-
draw short and sharp bursts of current, which alter ger runs, it’s better to use a higher voltage to dis-
the original AC sinusoidal wave. This altered wave tribute power as needed.
is now a nonlinear load and has odd harmonics that A 120/208 volt-wye is common for nonindus-
can become harmful to the transformer by increas- trial applications at the branch circuit level, but
ing the current in the windings resulting in excess the lower voltage makes it subprime for long-
distance distribution. Medium-voltage proper-
ties, where the voltage-to-ground is 1,000 volts
Table 1: Transformer efficiency or more, carry power from clusters of buildings
Single-phase Three-phase throughout the site.
Kilovolt-amperes % Kilovolt-amperes % Noise: Noise also should be considered,
depending on the type of building occupancy.
15 97.70 15 97.89
The constant vibrations from the transformer may
25 98.00 30 98.23
cause an undesirable audible hum for the client or
37.5 98.20 45 98.40 occupants. In a hotel tower occupancy, for exam-
50 98.30 75 98.60 ple, transformer rooms in the upper floors where
75 98.50 112.5 98.74 guestrooms are located may need sound-proofing
100 98.60 150 98.83
or acoustical treatment to mitigate noise from the
electrical space.
167 98.70 225 98.94
This room treatment may be avoidable if the
250 98.80 300 99.02 transformers are placed at grade level or on the
333 98.90 500 99.14 roof in a location that gives adequate separation
750 99.23 from the transformers and guests. Another solu-
1,000 99.28 tion could be to provide vibration-isolation pads
that reduce the noise to a level acceptable to the cli-
Table 1: The efficiency of a low-voltage dry-type distribution trans- ent. An acoustical engineer or consultant may be
formers is governed by the Department of Energy. Courtesy: NV5 involved to assist with this noise mitigation.

24 • December 2019 consulting-specifying engineer www.csemag.com

 Not all projects will follow the exact
methodology as described here, but may
expand to make further considerations.
No two properties are the same and as
such, no two projects will be the same.
It is the responsibility of the design
engineer to make the appropriate deci-
sions and consult with their client to
suit their needs. cse
Robert Sander is an electrical engineer
at NV5. He has experience in electrical
design of high-rise hospitality and PV.
Mario Caraveo is an electrical design-
er at NV5. Experience includes electrical
design for commercial offices, retail, hos-
pitality, industrial, mixed-use, residential
and health care.

Figure 5: An example of a pad-mounted

oil-insulated 300 kilovolt-amperes trans-
former is installed outdoors on a dedi-
cated equipment pad. Courtesy: NV5

There room construction is required

to meet requirements as outlined in
NEC Article 450 Part II. Specifically,
dry-type transformers installed indoors
require at least 12 inches of separation
from combustible material for trans-
formers rated less than 112.5 kilo-
volt-amperes, per NEC 450.21(A). For
dry-type transformers larger than 112.5
kilovolt-amperes, the room requires a
fire-resistant construction of at least one
hour per NEC 250.21(B).
However, there is an exception that
commonly applies: those with Class
155 or higher and completely encap-
sulated except ventilation openings
do not need to be located in one-hour
rated rooms. Figure 1 represents one of
these transformers; as such, the room it
resides in does not require a one-hour
fire-resistant rating.

Energy-efficiency requirements
Energy efficiency for dry-type dis-
tribution transformers is governed by
the U.S. Department of Energy. As such,
compliant transformers are labeled
with DOE-2016 to mark their compli-
ance since Jan. 1, 2017. Dependent on
the capacity of the transformer and its
quantity of phases, the efficiencies range
from 97.0% to 98.9% using 35% of the
nameplate-rated load. In addition to
the DOE requiring their label for com-
mercially available transformers, many
authorities having jurisdiction require
transformers specified to meet these
requirements.

December 2019  25
input #7 at www.csemag.com/information
 By Zia Salami, Ph.D., CDM Smith, Charlotte, N.C.; Lilly Vang, CDM Smith, Raleigh, N.C.; and
Adrian Hendels, CDM Smith, Boca Raton, Fla.
How to correctly
size a transformer
Engineers must make informed decisions regarding the proper transformer
sizing selection, electrical and mechanical requirements and impacts to the
electrical system under different operating and loading conditions
A
transformer is a major component of
an electrical distribution system with
the most impact on system perfor-
mance during steady-state (normal)
operation and during system distur-
bances, such as a fault. Therefore, engineers must
ensure that the transformer is appropriately sized
for the specific application and can supply adequate
power to the loads under designed conditions and
standard guidelines.
Typical applications for such major equipment are
industrial plants, commercial buildings,
L Learning hospitals, office buildings, shopping
centers, schools, apartment buildings,
OBJECTIVES etc. The article is focused on dry-type
• Learn major transformer transformer such as ventilated self-
characteristics, application and
cooled, forced air-cooled, nonventilat-
parameters.
ed self-cooled and sealed self-cooled
• Understand the major criteria
and approaches to determining
power transformers less than 30 mega-
proper transformer size. volt amperes and 34.5 kilovolts.
In general, dry-type transformers
• Learn how to use electrical
power system software to are less flammable (i.e., containing no
perform simulations. liquids or oil) and carry less of a fire
hazard, making them better suited for
use in and near buildings. This type of transform-
er has a higher operating temperature and typically
requires a larger footprint. Because dry-type trans-
formers require air for cooling, it is necessary to pro-
vide an adequately sized ventilation system for the
heat generated by the transformer.
The overall approach for sizing transformers
and related system impact are similar for all types of
transformer with different cooling classes.
Site location
Careful consideration must be taken when select-
ing the proper location for a transformer. Several
details, including transformer type, size, ventilation,
atmospheric pressure, altitude, voltage level and
clearance will have a determining factor in selecting
26 • December 2019 consulting-specifying engineer
the ideal location for the transformer required for a
given installation.
An engineer must be aware of the limitations due
to the selected location of a transformer. In general,
the kilovolt-ampere ratings are based on temperature
not to exceed 40°C ambient temperature (or ambient
temperature of 30°C averaged over a 24-hour peri-
od, otherwise some decrease in life expectancy will
occur) and also installed below 3,300 feet at sea level.
If any of these conditions are not met, transform-
er should be de-rated. In such case, transformer kilo-
volt-ampere should be de-rated by 8% for each 10°C
above 40°C (when air-cooled for dry-type transform-
er) and also by 0.3% for every 330 feet over 3,300 feet
altitude). More details for site consideration are dis-
cussed in NFPA 70: National Electrical Code Articles
450.8, 450.21 and 450.22.
Voltage class
The voltage class typically is selected based on
available source voltage (e.g., utility source) and the
required load voltage, if the load is designed to oper-
ate on a single- or three-phase system. The standard
rated high-voltage transformers are: 2,400, 4,160,
4,800, 6,900, 7,200, 12,000, 13,200, 13,800, 23,000
and 34,500 volts. The low-voltage side includes 208,
480, 2,400 and 4,160.
Winding connection and impedance
Standard connection arrangements and termi-
nal marking are included in the standards for par-
ticular types of transformers in accordance with
IEEE Standard C57.12.70. The most typical winding
(phase) connections for power transformers, includ-
ing angular displacement between high- and low-
voltage, is shown in Figure 1. Based on this standard,
the angular displacement of three-phase transform-
ers with delta-delta or wye-wye connections shall be
0 degrees and wye-delta or delta-wye connections
shall be 30 degrees.
www.csemag.com
 Figure 1: The most
typical winding
(phase) connections
for power trans-
formers, including
angular displace-
ment between high-
and low-voltage are
shown. Courtesy:
CDM Smith

‘The grounding configuration

and scheme depends on the
overall neutral grounding

’
system in the facility.
In general, the selection of winding connections is
mainly based on the overall system design, required
system parameter (e.g., equipment short-circuit cur-
rent withstand capability) and especially the system
neutral grounding scheme. In addition, wye-connec-
tion can configure as one of the grounding types such
as open (ungrounded), solid (solidly grounded, no
intentional impedance in the neutral grounding path),
resistor (a resistor is used in the neutral grounding
path), reactor (a reactor is used in the neutral ground-
ing path) and few other less applicable options.
The grounding configuration and scheme
depends on the overall neutral grounding system in
the facility. A wye solidly grounded transformer (sec-
ondary) is a typical application in facilities for a low-
voltage system (e.g., 4.16 kilovolt:0.480 kilovolt).
In addition, Z (impedence, based on transformer
self-cooled kilovolt-ampere ratings) is typically shown Figure 2: The three-phase electrical distribution system ETAP model
on nameplate information that is attached to front or for a typical industrial facility, such as a water treatment plant, is
inside transformer enclosure. This value has a high shown. Courtesy: CDM Smith
impact on electrical distribution system parameters
such as voltage drop, available short circuit and inci-
dent energy. For example, choosing a higher impen- and low-side transformer voltage ratings. For instance,
dence transformer (i.e., from 5.5% to 7.5%) can lower %Z for transformer with high-voltage side less than 34.5
the available fault current allowing for equipment with kilovolts is between 5.5% and 7.5%. Note that the typi-
lower amperes interrupting ratings, as long as there cal %Z for 13.8 kilovolts (or less) on the high side and
are no issues with system voltage within a facility. 2.4 kilovolts (or less) on the low side is 5.75%.
ANSI C57.12.10 specifies typical impedance values Most industry power transformers are included
for transformers larger than 500 kilovolt-amperes. This in this voltage level range. For a transformer less or
value depends on kilovolt-ampere rating and also high- equal to 500 kilovolt-amperes, a typical %Z imped-

www.csemag.com consulting-specifying engineer December 2019 • 27

 ance may vary between 2.3% and 5.2% based on the
voltage level. For instance, a 100 kilovolt-ampere
transformer with 8.32 kilovolts (or less) on the high
side has a typical value of 2.6% impedance.
Transformer sizing for new systems
Due to the critical role of transformers in elec-
trical distribution systems, it is essential that the
transformer is sized correctly so that it can meet
all applicable loading conditions. If it is under-
sized, it may create issues within electrical distri-
bution systems, including loss of loads. In general,
transformer sizing can be performed based on two
methods:

Table 1: Three-phase 4.16:0.480 kilovolt sizing with load factor 1

Kilovolt-
Loads for LV Rated Rated Rated Power Load Load
Voltage Efficiency ampere
XFMR horsepower kilowatts amperes factor factor descriptions
ratings
Motor, service
Motor 1 480 100 0.9 0.93 1 89.1
factor (SF)=1
Motor 2 480 50 0.9 0.93 1 44.5 Motor, SF=1
Motor 3 480 10 0.9 0.93 1 8.9 Motor, SF=1
Lighting/
Load 3 480 20 1 1 1 20.0
computer
Load 4 480 40 1 1 1 40.0 Heater
Panel 1 480 200 1 1 1 166.3 Panel
Total All connected
369
kilovolt-ampere loads
Including load
20% reserve 443
growth
Transformer
Standard size
kilovolt-ampere 500
available
rating

Table 1: The individual loads with their corresponding system parameters such as rated horsepower, power factor,
efficiency and a load factor of 1 are tabulated to determine the low-voltage transformer size. Courtesy: CDM Smith

Table 2: Three-phase 13.8:4.16 kilovolt sizing with load factor 1

Kilovolt-
Loads for ser- Rated Rated Rated Power Load Load
Voltage Efficiency VFD pf VFD eff ampere
vice XFMR horsepower kilowatts amperes factor factor descriptions
rating
Pump No. 1 4,160 600 0.85 0.9 1 584.9 Motor, SF=1
Pump No. 2 4,160 250 0.85 0.95 1 230.9 Motor, SF=1
Motor with
Pump No. 3 4,160 600 0.85 0.9 0.95 0.97 1 539.5
VFD 1
Load 1 4,160 200 1 1 1 200.0 Heater
Lighting/
Load 2 4,160 100 1 1 1 100.0
computer
LV XFMR 4,160 1 500.0 LV XFMR
Total kilovolt- All connected
2,155
ampere loads
20% reserve 2,486 Including load 2
Transform-
Standard size
er kilovolt- 2,500
available
ampere rating

Table 2: The individual loads with their corresponding system parameters such as rated horsepower, power factor, effi-
ciency and a load factor of 1 are tabulated to determine the medium-voltage transformer size. Courtesy: CDM Smith
Note 1: Motor kilovolt-ampere with variable frequency drive: Motor kilovolt-ampere rating x (motor power factor/vari-
able frequency drive/VFD efficiency). Note that the difference kilovolt-ampere required ratings between two similar
600 horsepower motors (pumps No. 1 and 3), one with VFD (pump No. 3) and one direct connection. VFD improves sys-
tem efficiency in the system and consequently less required motor kilovolt-ampere when it is installed.
Note 2: 500 kilovolt-ampere LV XFMR has already included 20% margin. Courtesy: CDM Smith

28 • December 2019 consulting-specifying engineer www.csemag.com

 • Connected load.
• Operating load.

In both cases, load growth and future facility modi-

fication and de-rating factors such as ambient temper-
ature and altitude should be considered. The growth
factor is typically based on each system design and
can vary; 110% to 130% is a reasonable range. In both
methods, the sizing is performed from the downstream
system to the main transformer (i.e., bottom up).
The difference between these two methods is to
determine a total connected kilovolt-ampere loads.
There are several considerations that will determine
which method to use, such as required design mar-
gin, project specification, cost, space availability and
impact on voltage drop and available fault current.
The electrical distribution system of a typical
industrial facility, such as a water treatment plants, is
shown in Figure 2. The task is to evaluate the size of
the new ventilated self-cooled transformer (or eval-
uate the size for the existing), based on its required
loads, using the two methods previously mentioned.
For sizing based on all connected loads, the con-
servative method, all connected loads are considered
regardless of their operating condition and system
function. The sizing is performed from the down-
stream transformer toward the main. As shown in Figure 3: Power (kilovolt-ampere) flow for each branch including
Figure 3, the downstream transformer (LV XFMR) percent voltage (of nominal rating) and fault current for the major
is three-phase at 4.16 to 0.480 kilovolts, and the main switchgear and motor control center is shown. Courtesy: CDM Smith
transformer (service XFMR) is three-phase 13.8 to
4.16 kilovolts supply to different type loads (e.g.,
motor loads, variable frequency drives, static loads,
distribution panel).
The individual loads with their corresponding
system parameters such as rated horsepower, power
factor, efficiency and load factor are tabulated in
Tables 1 and 2. Total kilovolt-ampere of the connect-
ed system is calculated including design margin and
then the next available standard size will be selected.
The typical standard size kilovolt-ampere for
three-phase transformer based on ANSI C57.12.00
typically range between 15 and 100,000 kva which
are based on the output of the transformer. The input
kilovolt-ampere is expected to be higher by 1% to 5%
(i.e., refers to transformer efficiency) due to trans-
former losses in its core and windings, dissipated as
heat. These flows for each transformer are shown in
Figures 3 and 4.
In general, unless specified, transformers should
not be overloaded and should be approved by the
manufacturer for any short-time overloading opera-
tion due to the lower ambient temperature.
The evaluation of data and kilovolt-ampere trans-
former selected size tableted in these tables are
confirmed and analyzed by performing load flow
analysis using ETAP electrical software. Power (kilo-
volt-ampere) flow for each branch including percent Figure 4: Power flow and short-circuit results for a system based on actual
voltage (of nominal rating) and fault current for the system operations were calculated using ETAP. Courtesy: CDM Smith

www.csemag.com consulting-specifying engineer December 2019 • 29

 major switchgear and motor control center is shown
in Figure 3.
For sizing based on actual system operations, all
connected loads will be considered based on their
operating conditions (i.e., load factors). As with con-
nected loads, the sizing is performed from the down-
stream transformer toward the main with the same
process. Total kilovolt-ampere including design mar-
gin, load factors and the selected transformer size are
calculated and shown in Tables 3 and 4.
The evaluation of the same system with differ-
ent transformer sizes is shown in Figure 4. Power
flow for each branch including percent voltage and
fault current are also shown for the major switch-
gear and MCC.
In addition, there are a few results that should
be noted when comparing Figures 3 and 4. First,
the connected loads method is a more conservative
approach when sizing the transformer and will pro-
vide better system voltage profile on the secondary
side, but it generates and injects more fault current.
This is mainly due to higher kilovolt-ampere trans-
former rating and consequently higher short-circuit
injection to the system.

Table 3: Three-phase 4.16:0.480 kilovolt sizing with different load factor

Kilovolt-
Loads for LV Rated Rated Rated Power Load Load
Voltage Efficiency ampere
XFMR horsepower kilowatts amperes factor factor descriptions
ratings
Motor 1 480 100 0.9 0.93 0.85 75.7 Motor, SF=1
Motor 2 480 50 0.9 0.93 0.85 37.9 Motor, SF=1
Motor 3 480 10 0.9 0.93 0.85 7.6 Motor, SF=1
Lighting/
Load 3 480 20 1 1 0.6 12.0
computer
Load 4 480 40 1 1 0.7 28.0 Heater
Panel 1 480 200 1 1 0.5 83.1 panel
Total
244 Operating loads
kilovolt-ampere
Including load
20% reserve 293
growth
Transformer
Standard size
kilovolt-ampere 300
available
rating

Table 3: The individual loads with their corresponding system parameters such as rated horsepower, power factor, effi-
ciency with different load factors are tabulated to determine the low-voltage transformer size. Courtesy: CDM Smith

Table 4: Three-phase 13.8:4.16 kilovolt sizing with different load factor

Kilovolt-
Loads for Rated Rated Rated Power Load Load
Voltage Efficiency VFD pf VFD eff ampere
service XFMR horsepower kilowatts amperes factor factor descriptions
ratings
Pump No. 1 4,160 600 0.85 0.9 0.8 467.9 Motor, SF=1
Pump No. 2 4,160 250 0.85 0.95 0.75 173.2 Motor, SF=1
Motor with
Pump No. 3 4,160 600 0.85 0.9 0.95 0.97 0.8 431.6
VFD
Load 1 4,160 200 1 1 0.7 140.0 Heater
Lighting/
Load 2 4,160 100 1 1 0.6 60.0
computer
LV XFMR oper-
LV XFMR 4,160 1 244.0
ating loads
Total kilovolt- Operating
1,517
ampere loads
Including load
20% reserve 1,820
growth
Transformer
Standard size
kilovolt- 2,000
available
ampere rating

Table 4: The individual loads with their corresponding system parameters such as rated horsepower, power factor, effi-
ciency with different load factors are tabulated to determine the medium-voltage transformer size. Courtesy: CDM Smith

30 • December 2019 consulting-specifying engineer www.csemag.com

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input #8 at www.csemag.com/information
Codes and standards for transformers
The following technical codes and standards are applicable to and should be considered when selecting and
evaluating the overall performance of a transformer, specifically dry-type power transformers:

%


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 General off a Dry-Type Transformer Coil.
General Applications. Requirements for Dry-Type Distribution
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Guide for Test
and Power Transformers, Including Those
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 IEEE Guide for Procedures for Thermal Evaluation of
with Solid-Cast and/or Resin Encapsulat-
Transformer Impulse Tests. Insulation Systems for Solid-Cast and Res-
ed Windings.
in-Encapsulated Power and Distribution
%


$ "

 IEEE Standard
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$ "

 Requirements Transformers.
Terminology for Power and Distribution
for Ventilated Dry-Type Power Transform-
Transformers. %


$ "


IEEE Standard
ers, 501 Kilovolt-Amperes and Larger,
for General Requirements for Liquid-
%


$ "


 IEEE Stan- Three-Phase, with High-Voltage 601 to
Immersed Distribution, Power and Regu-
dard for Standard Terminal Markings and 34 500 Volts, Low-Voltage 208Y/120 to
lating Transformers.
Connections for Distribution and Power 4160 Volts.
Transformers. %


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 Standard
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 Transform-
Test Code for Dry-Type Distribution and
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 IEEE Guide ers — Used in Unit Installations, Includ-
Power Transformers.
for Dry-Type Transformer Through-Fault ing Unit Substations — Conformance
Current Duration. Standard. %


$ "

 IEEE Recom-
mended Practice for Establishing Liq-
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 IEEE Guide for %


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 Standard Test
uid-Filled and Dry-Type Power and
Loading Dry-Type Distribution and Power Procedure for Thermal Evaluation off Insu-
Distribution Transformer Capability When
Transformers. lation Systems for Ventilated Dry-Type
Supplying Nonsinusoidal Load Currents.
Power and Distribution Transformers.
%




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$"
! Arti-
cle 450, Transformers and Transformer %


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input #9 at www.csemag.com/information
 Second, typical power transformers are
equipped with fixed taps (i.e., two 2.5% taps above
rated voltage and two 2.5% taps below rated volt-
age) that are designed to adjust the transformer
voltage at the primary or secondary side. There-
fore, it is recommended to use this capability to
increase (or decrease) system voltage if needed.
For instance, voltage at the MCC bus in Figure 4
can be increased by 2.5% or 5% if desired. Howev-
er, a system designer should be careful not to solve
one issue (i.e., system voltage profile) and simul-
taneously create another issue (i.e., injecting more
fault current by increasing system voltage). In addi-
tion to fixed taps, transformer could be equipped
with automatic load tap changer which provide
wider range typically -10% to +10% of the wind-
ing kilovolt with smaller step (0.625%) to adjust
and control the bus voltage based on desired volt-
age value.
It is also important to point out that a K-factor
rated transformer is recommended to size the trans-
former due to heat generation if the facility contains
high harmonic generating sources, typically more
than 15% total harmonic distortion. The K-factor
will determine how much a transformer should be
de-rated or oversized to handle such a system. Refer
to ANSI/IEEE C57.110 for more details.
Transformers play a critical role in ensuring
proper power system operation. They should be
carefully sized and selected when designing and
analyzing electrical distribution system to pro-
vide reliable and safe power system operation.
The proper transformer sizing should consider
applicable de-rating factors such as ambient tem-
perature and altitude and, in addition, impacts
on electrical distribution system voltage and fault
current contribution. cse
Zia Salami is a subject matter expert in electrical
power systems at CDM Smith. Salami has more than
20 years of industry and academic experience in elec-
trical power systems and has served in several roles
as an advisory engineer, consultant and academic
professor.
Lilly Vang is a junior electrical engineer at CDM
Smith, where she focuses on electrical power system
design and analysis.
Adrian Hendels is a junior electrical engineer at CDM
Smith, where he focuses on electrical power system
design and analysis.

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BUILDING SOLUTIONS
CODES AND STANDARDS
By Vahik Davoudi, PE, LEED AP BD+C, Arup, Los Angeles

Analyzing
NEC 2017 changes
Several changes to the 2017 edition of NFPA 70:
National Electrical Code should be noted

T
he 2017 edition of NFPA 70: National
Electrical Code went through exten-
sive changes as part of the three-year
code cycle to incorporate revisions
resulting from the public inputs and
public comments. Every code cycle, the NFPA
goes through rigorous efforts to update NFPA 70
— to keep up with new technologies and trends
in the electrical industry — while maintaining the
goal of facilitating the safe installation of electrical
wiring and equipment.
The 2017 NEC revision pro-
along with 666 editorial comments to the first draft.
Subsequently, 1,513 public comments were submit-
ted that resulted in 559 second revisions to the sec-
ond draft of NEC.
New articles added to NEC
There were nine new articles proposed for this
code cycle, but only five new articles were adapted
and included in the 2017 NEC:
• Article 425: Fixed Resistance and Electrode
Industrial Process Heating Equipment: Pres-

L Learning cess itself was changed during this

code cycle in an attempt to improve
ents needed regulations for industry.

OBJECTIVES the overall process. In general, there • Article 691: Large-Scale Photovoltaic Electric
• Understand the revision process are two public meetings held for the Supply Stations: Addresses the requirements for
for NFPA 70. NEC revision process during each large-scale PV systems (5 megawatts or higher)
• Review a general analysis of code cycle. The first public meeting generation capability that are solely connected
changes to the 2017 edition of now known as “first draft,” replac- to the utility grid.
NFPA 70. ing “report and proposals,” is held
• Learn about the implications of when all suggested changes to NEC
some revisions on the design of are discussed. The suggested changes
electrical systems. now known as “public inputs,” replac-
ing “proposals,” that were acted upon
favorably resulted in first revisions to the “first draft”
of the 2017 NEC.
The second public meeting now known as “sec-
ond draft,” replacing “report and comments,” is held
when all comments are heard. The new comments
now known as “public comments,” replacing “sug-
gested comments” that were successful resulted in
“second revisions” to the second draft.
After the two meetings, appeals were heard and
voting for acceptance of the 2017 NEC took place
at the NFPA Annual Conference & Expo in June
2016, which then paved the way for NFPA Standards
Council to issue the 2017 NEC by August 2016.
According to NFPA, there were 4,012 public inputs
submitted recommending changes to the 2017 edi- Figure 1: A primary current injection testing
tion of the NEC that resulted to 1,235 first revisions wiring diagram is shown. Courtesy: Arup

36 • December 2019 consulting-specifying engineer www.csemag.com

Figure 2: The addition of new sub-
section into 2017 edition of the
National Electrical Code to clarify
the requirements for a permanent
switching means for emergency
systems that rely on a single
alternate source of power. Shown
here is a generator quick-connect
switchboard Courtesy: Schneider
Electric
• Article 706: Energy Storage Sys-
tems: Addresses the require-
ments for ESS operating at more
than 50 volts alternating current
or 60 volts direct current that
can operate independently or
interactive with power produc-
tion sources.
• Article 710: Stand-Alone Sys-
tems: Addresses the requirements for power
production sources operating in stand-alone
mode that are not connected to the grid.
• Article 712: Direct Current Microgrids:
Addresses requirements for independent ener-
gy distribution networks that allow the use of
power from DC sources to DC loads.
Top 10 code changes
Branch circuits — general provisions: Sec-
tion 210.8(B) — Ground-Fault Circuit Interrupt-
er Protection for Personnel, Other than Dwelling
Units. The GFCI requirements for receptacles
at commercial and industrial applications have
been expanded to require ground fault protec-
tion for circuits beyond 15 and 20 amperes at 125-
volt applications. The code now mandates that at
“other than dwelling units” all single-phase recep-
tacles rated 150 volts to ground or less and up to
50 amperes shall be equipped with GFCI devices.
Whereas three-phase receptacles rated 150 volts
to ground or less and up to 100 amperes require
GFCI protection devices.
The Class “A” GFCI devices, which are designed
to trip when the current to ground exceeds 4 to 6
milliamperes, have been critical safety features that
have reduced the number of injuries and fatalities
due to electrical shock since their inclusion into the
1968 NEC. Major equipment manufacturers pro-
vide single-phase GFCI circuit breakers through
50 to 60 amperes, but nothing higher and certain-
ly they have no three-phase GFCI circuit breakers.
There are some alternate UL listed products avail-
able in the market that could be considered to pro-
vide GFCI protection to people for higher ampere
rating single-phase and three-phase circuit appli-
www.csemag.com
cations. Generally, these devices are
located between the circuit break-
er and the load and are self-powered
with a protective relay and a con-
tactor to open the circuit when the
ground fault exceeds 5 milliamperes.
Branch-circuit, feeder and ser-
vice load calculations: Section
220.12 — Lighting Loads for Speci-
fied Occupancies. Exception No. 1
of Section 220.12 was introduced in
2014 NEC, which allowed lighting
loads to be calculated based on ener-
gy code adopted by local authorities
while meeting three listed condi-
tions. New exception No. 2 added
to 2017 NEC expands this allowance
where an energy code is adopted and
that energy code specifies an overall
lighting density of less than 1.2 volt-
amperes/square foot. It permits the
unit lighting loads in Table 220.12
for office and bank areas within the building to be
reduced by 1 volt-amperes/square foot.
‘ The 2017 National Electrical Code
revision process itself was changed during
this code cycle in an attempt to improve
’
the overall process.
Article 220 provides specific requirements for
calculating branch-circuit, feeder and service loads.
The title and scope were revised somewhat to
enhance clarity of what is covered by the article and
to emphasis on calculating loads in this article and
deferring the branch circuit and conductor sizes to
Articles 210 and 215. The recent changes that allow
lighting loads to be calculated using adopted energy
codes are significant steps in the right direction to
reduce the electrical service size and thereby cost of
equipment. Hopefully, the type of occupancies list-
ed in exception No. 2 will expand in the near future
to avoid having many buildings or tenants with
oversized service.
Services — Service Equipment Overcurrent
Protection: Section 230.95(C), Ground-Fault Pro-
tection of Equipment — Performance Testing. The
performance testing requirement for ground-fault
protection system has been modified to ensure the
testing is conducted by a qualified person(s) using a
test process of primary current injection and that
a written record of this testing is available to the
authority having jurisdiction. This requirement
also affects feeders listed under Section 215-10.
consulting-specifying engineer December 2019 • 37
BUILDING SOLUTIONS
CODES AND STANDARDS

The addition of testing requirements was the
result of many failures due to ground-fault protec-
tion systems that were improperly connected and
did not function properly to provide the intend-
ed protection. The addition of testing by qualified
persons and proper documentation of test results
and making it readily available to AHJ for review
should eliminate all the concerns related to GFPE.
Overcurrent Protection — Fuses: Section
240.67 — Arc Energy Reduction. The code expands
the requirement for arc energy reduction where
fuses rated 1,200 amperes or higher are installed.
This requirement will become effective Jan. 1, 2020.
This is similar to Section 240.87 that was added to
the 2011 NEC to reduce incident energy for circuit
breakers rated 1,200 amperes and higher.
This new requirement will reduce incident
energy to which an electrical worker or mainte-
nance personnel could be exposed when work-
ing on the load side of an overcurrent device — in
this case, fusible switches. Unfortunately, no man-
ufacturers have developed fusible switches with
an energy-reducing maintenance switching fea-
ture with local status indicator, like what is avail-
able in the market for circuit breakers. This will
impact the installation costs where in lieu of a
low-cost fuse, a more expensive circuit breaker
with energy reduction maintenance switch has to
be considered.
Overcurrent Protection — Circuit Breakers:
Section 240.87 — Arc Energy Reduction. The sub-
section (B), which covers requirements for reduc-
ing clearing time on breakers rated 1,200 amperes or
more, describes three new permissible methods. Two
of the three new means involve using an “instanta-
neous trip setting” or “instantaneous override” that is
less than the available arcing current, while the third
option allows “an approved equivalent means.”
This section was originally added to 2011 NEC
to reduce incident energy for circuit breakers rated
1,200 amperes and higher to limit the arc-flash
energy. The new methods of reducing arc flash
energy required under 2017 NEC at first glance
offer substantial savings compared to the ones list-
ed under 2014 NEC by using trip unit with arc flash
reduction switch, which may not be the case for
many situations.
Now, instead of an expensive trip unit with arc
flash reduction switch, a standard instantaneous
adjustment dial could be used, if the breaker’s fixed
instantaneous override or instantaneous trip setting
can be set below the calculated available arcing cur-
rent. However, unlike the four methods listed under
2014 NEC, the two new methods have performance

Overview of changes throughout NEC

Some of the most notable changes
impacting 2017 edition of NFPA 70:
National Electrical Code are:
• All definitions that appeared in two or
more articles have been relocated to
Article 100.
• New requirements have been added
for the use of calibrated tightening
torque tools for electrical connections,
where a torque value is indicated on
equipment or listed in installation
manual by the manufacturer.
• New labeling requirements, such as
detailed arc flash hazard warning on
equipment to help assess electrical
risks, have been added per Section
110.16(B).
• New Section 110.21(A)(2) requires
reconditioned equipment to be
marked with the name, trademark or
other descriptive marking, identify-
ing the organization responsible for
reconditioning the electrical equip-
ment including the date of the recon-
ditioning.
• New Section 110.26(A)(4) addresses
access and space clearances required
for equipment that by installation
instructions or function is located in a
“limited access location.”
• The migration from 600 volts to
1,000 volts that started with 2014
NEC continues, all relative to the cur-
rent trends in the electrical industry.
These changes have been primarily
in response to renewable energy sys-
tems that operate over 600 volts and
the NEC lacked requirements to safely
cover these systems.
• New and revised provisions for arc-
fault circuit interrupter and ground-
fault circuit interrupter protection to
improve electrical and fire safety at
homes have been addressed per Sec-
tions 210.12 (C) and (D).
• New Section 210.11(C)(4) requires
at least one 20-ampere rated branch
circuit to supply dwelling unit garage
125-volt receptacle outlet(s).
• New Section 210.71 requires a
minimum number of receptacles to
be installed in meeting rooms not
exceeding 1,000 square feet.
• Revisions made to the acceptable
grounding electrode system for a
separately derived system listed under
Section 250.30(A)(4). The metal water
piping and structural metal grounding
electrodes are no longer mandatory
and now any of the building or struc-
ture grounding electrodes described
at Section 250.52(A) can be used as
the grounding electrode for sepa-
rately derived system. As a matter of
fact, the water pipe and the structural
metal frame per Section 250.68(C) are
not considered grounding electrodes
but rather are conductors extending

38 • December 2019 consulting-specifying engineer www.csemag.com

requirements to demonstrate the effectiveness of this
procedure. There has to be a short-circuit, coordi-
nation and arc-flash study prepared for verification
that indeed the breaker settings can be set below the
calculated available arcing current. The use of low-
er-cost breakers with standard instantaneous adjust-
ment dial may be economical for some projects,
however for larger complex buildings the addition-
al cost for studies could easily wipe out any sav-
ings expected depending on the number of breakers
involved.
Health Care Facilities — Essential Electrical
Systems, Sources of Power: Section 517.30(B)(2) —
Types of Power Sources — Fuel Cell Systems. Accord-
ing to the new subsection, a battery system is no
longer permitted as an alternate source of power, while
the fuel cell systems will be permitted as the alternate
source for a health care facility, provided that they:

• Meet the requirements for fuel cell

systems in Article 692.
• Meet the redundancy requirement.
• Meet the 10-second rule.
• Meet the fuel supply requirements.
Figure 3: Devices like this emergency lighting
branch circuit transfer relay will now be evaluat-
ed to the performance and construction require-
ments that is applied to traditional emergency
transfer switches for use on branch circuits rated
up to 20 amperes. Courtesy: Ecoflex Solutions

the grounding electrode connection.
• Revisions made to Section 310.15(B)
(3)(c) requires a minimum of 7/8 inch
clearance from the roof surface for
raceways and cables or else they will
be subject to 60°F temperature adder.
The old temperature adder table has
been removed.
• Revisions made to Section 406.12
expand the list of spaces requiring the
use of tamper-resistant 125- and 250-
volt, nonlocking 15- and 20-ampere
receptacles.
• New Section 422.6 requires that all
appliances operating at 50 volts or
more to be listed.
• All battery management equipment
and batteries, except lead-acid, must
be listed per Section 480.3.
• Electrical metallic tubing is no longer
allowed for installation in Class 1, Divi-
sion 2 areas per Section 501.10(B)(1).
• The surge protection device require-
ments have been expanded beyond
emergency power systems to include
protection for specific elevators, criti-
cal operations power systems and for
industrial machinery per Sections
620.51(E), 645.18 and 670.6.
• New requirements added throughout
the NEC involving the documentation
of the available short-circuit current
at specific types of equipment (e.g.,
motor control centers, air condition-
ing equipment, elevators, industrial
machinery and industrial control pan-
els) and the date the short-circuit
current calculation was performed.
The documentation for the calculation
required for the short-circuit current
marking must be made available to
the owner and to anyone maintain-
ing or operating the facility and more
importantly to the authority having
jurisdiction.
• The recent developments and growth
in the renewable power systems gen-
eration and storage technologies have
resulted to significant changes to the
existing Article 690 along with addi-
tion of four new articles 691, 706, 710
and 712, all mentioned earlier.
• The short-circuit current rating of the
transfer equipment, based on the
specific overcurrent protective device
type and settings protecting the trans-
fer equipment, shall be field marked
on the exterior of the transfer equip-
ment per Sections 700.5(E), 701.5 (D)
and 702.5.
• New Section 725.144 has been added
to address requirements for types
of Class 2 and 3 cables for transmis-
sion of data and power to connected
devices. This is commonly referred to
as power over Ethernet and is becom-
ing very popular for many applications
such as circuiting for LED lighting.

www.csemag.com consulting-specifying engineer December 2019 • 39

BUILDING SOLUTIONS
CODES AND STANDARDS
• Have a connection for a portable diesel
generator.
• Are listed for emergency system use.
The fuel cell systems will now be permitted to
serve all or part of an essential electrical system.
The requirements for sources of power for essen-
tial electrical system of a health care facility was
located at article 517.35 of NEC 2014, which as a
minimum required two independent sources of
power — a normal power source and one or more
alternate power sources for use when the normal
power source is interrupted. For the 2017 NEC, the
requirements for two independent sources of power
and an alternate source of power for the essen-
tial electrical system for health care facilities were
revised and relocated to article 517.30. The most
notable change was the addition of fuel cell systems
to the list of acceptable sources of alternate power.
Emergency Systems — Tests and Maintenance:
Section 700.3(F) — Temporary Source of Power for
Maintenance or Repair of the Alternate Source of
Power. According to the new subsection (F), if the
emergency system relies on a single alternate source
of power, which will be disabled for maintenance
or repair, the emergency system shall include per-
manent switching means to connect a portable or
temporary alternate source of power, which shall
Figure 4: Part IV was added to Article 705 of the 2017 edition of the
National Electrical Code to address all the issues related to microgrid
systems as an interconnected electric power production source. This
shows a microgrid distribution plan. Courtesy: Arup
40 • December 2019 CONSULTING-SPECIFYING ENGINEER
be available for the duration of the maintenance or
repair. The permanent switching means to connect
a portable or temporary alternate source of power
shall comply with five provisions listed in the code.
It shall be permissible to use manual switching
to switch from the permanent source of power to
the portable or temporary alternate source of power
and to use the switching means for connection of a
load bank.
There was a statement at the end of section
700.4(B) of 2014 NEC that said, “A portable or tem-
porary alternate source shall be available whenever
the emergency generator is out of service for major
maintenance or repair.” However, there were no
prescriptive requirements provided for this require-
ment in 2014 NEC, causing confusion, which
resulted in the addition of new subsection into 2017
NEC to clarify the requirements for a permanent
switching means for emergency systems that rely
on a single alternate source of power.
Emergency System — Circuit Wiring: Section
700.10(D) — Fire Protection. According to modi-
fied subsection (D), emergency systems shall meet
the additional requirements in (D)(1) through (D)
(3) in the following occupancies:
• Assembly occupancies for not less than
1,000 persons.
• Buildings above 75 feet in height.
• Health care occupancies where persons are not
capable of self-preservation.
• Educational occupancies with more
than 300 occupants.
The subsection 700.10(D) in 2017 NEC was
expanded by adding Health care and Educational
occupancies to the requirements for fire protection
of emergency system feeders in addition to high-rise
buildings and buildings with high occupancy loads.
All efforts shall be made at the engineering, design-
ing, plan review and construction stages of a project
for the protection of emergency circuits in Health
care and other listed occupancies from damage due
to a fire. The fire protection methods employed
shall provide a minimum two-hour fire rating for
the emergency cables or raceways and contain only
emergency wiring circuits as required.
Emergency Systems — Control of Emergency
Lighting Circuits: Section 700.25 — Branch Circuit
Emergency Lighting Transfer Switch. A new defini-
tion along with provisions and requirements have
been added to the 2017 edition as part of the rea-
son to introduce the new branch-circuit emergency
lighting transfer switches into the code. Emergen-
cy lighting loads supplied by branch circuits rated
www.csemag.com
at not greater than 20 amperes shall be permit-
ted to be transferred from the normal branch cir-
cuit to an emergency branch circuit using a listed
branch circuit emergency lighting transfer switch.
The mechanically held requirement of 700.5(C) shall
not apply to listed branch circuit emergency lighting
transfer switches.
Section 700.25, along with its definition
described in section 700.2, were added to ensure
code compliant devices under UL 1008 standards
are used. These devices will now be evaluated to the
performance and construction requirements that is
applied to traditional emergency transfer switches
for use on branch circuits rated up to 20 amperes.
In the past there were no clear definition or require-
ments stated in the code and over the years auto-
matic load control relays have been used to transfer
emergency lighting loads from the normal supply
to an emergency supply even though this is not in
compliance with section 700.26. The addition of
section 700.24 to 2011 NEC did not clearly address
the issue, but now the addition of 700.26 in the
2017 NEC shall eliminate any misunderstanding of
the code intent.
Interconnected Electric Power Production
Sources: Article 705, Part IV — Microgrid Systems.
The microgrid systems also referred to as “inten-
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tionally islanded systems” and “stand-alone systems”
have been getting a lot of recognition in recent years
as a way to reduce energy usage, lower cost and,
more importantly, add resiliency against the loss of
utility power. Microgrids are small wiring systems
consisting of generation, energy storage and load(s)
or any combination thereof that shall be permitted
to disconnect from the primary source of power
or other interconnected electric power production
sources and operate as a separate microgrid system.
The 2014 NEC did not clearly address the
installation of microgrid systems and a new Part IV
was added to Article 705 of 2017 NEC to address
all the issues related to microgrid systems as an
interconnected electric power production source.
The code changes/additions are in response to the
recent developments in microgrid systems indus-
try to further develop a flexible and efficient elec-
tric grid, by enabling the integration of growing
deployments of renewable sources of energy such
as solar and wind and distributed energy resources
such as combined heat and power, energy storage
and demand response. cse
Vahik Davoudi is an associate principal at Arup. He
is an expert at codes and energy standards with more
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BUILDING SOLUTIONS
CASE STUDY
By David B. Korzuch Jr., PE; and Christopher J. Barbieri, PE, CRB, Philadelphia
Energy-efficient
clean rooms
Designers formulated several energy-saving strategies that can be implement-
ed into the HVAC system design of a pharmaceutical-grade clean room suite
H
eating, ventilation and air condition-
ing systems account for a large per-
centage of the total energy use in a
typical commercial building. Func-
tionally intensive buildings, such as
pharmaceutical and biotechnology manufacturing
facilities, consume much more energy per square
foot and often take exception to energy-efficient
building codes that typically apply to the design of
commercial buildings.
The average commercial office building built
after 2000 has an average energy use intensity of
81.4 Btu/square foot (257 kilowatt hours/square
meter) The average pharmaceutical plant has an
EUI of 1,210 Btu/square foot (3,819 kilowatt hours/
square meter). This is due to the fact that these
types of facilities consume energy to
maintain clean room environments,
L Learning to power production equipment and
OBJECTIVES to power large utility generation
• Learn about the energy-efficient equipment.
design strategies that should An increasing number of proj-
be considered for a clean room ects have attention focused on ener-
HVAC system. gy reduction initiatives, such as
• Understand the energy use of green building certification and cli-
each clean room design strategy ent-mandated energy benchmarks.
and how each one compares to
a traditional design approach.
These are structured around corpo-
rate goals and strategies for sustain-
• Evaluate the most common
HVAC system design
ability and reduced carbon footprint.
approaches to consider for It’s no surprise that energy reduction
maintaining a clean room requirements similar to the design of
environment. commercial buildings are unavoid-
able and must be accomplished using
atypical strategies that take engineers, designers and
clients out of their realm of comfort.
Overdesigning and oversizing mechanical sys-
tems will directly result in higher capital and oper-
ating costs as well as facilities with higher carbon
footprints. Increased emphasis on total building
performance and energy code compliance, coupled
42 • December 2019 consulting-specifying engineer
with corporate sustainability goals, will be the man-
date for the industry moving forward.
Energy codes
Energy codes are adopted at a local or state level.
These codes establish minimum energy-efficien-
cy requirements and other baseline requirements
related to building construction. The Internation-
al Energy Conservation Code is the most wide-
ly adopted energy code in the United States. The
IECC establishes a baseline for energy efficiency by
setting performance standards and requirements
for the building envelope as well as the mechanical,
electrical and plumbing systems (in both residential
and commercial settings). ASHRAE Standard 90.1:
Energy Standard for Buildings Except Low-Rise
Residential Buildings has been the benchmark for
commercial building codes for the past few decades
and is often adopted as code through the IECC.
The IECC contains three basic options or
approaches for commercial buildings:
• Meet the requirements of ASHRAE 90.1.
• Meet IECC prescriptive provisions.
• Meet IECC total building performance
provisions.
In the past, there has been debate over the appli-
cability of energy codes developed for commercial
buildings as they relate to more industrial facilities.
As states have adopted green building and ener-
gy codes, industrial facilities are generally directly
included and fall under the jurisdiction of the code.
There has been a rapid progression and devel-
opment of energy codes and standards since 2010.
Selective compliance and questions over code appli-
cability will become a distant memory as energy
codes are further refined.
www.csemag.com
Figure 1: An open clean room design was programmed for flexibility to allow for future reconfiguration of low wall
return chases and high-efficiency particulate air supply terminals. Courtesy: CRB

According to Pacific Northwest National Labo-

ratory, the three most recent editions of the IECC
and ASHRAE 90.1 have the potential to generate
almost a 30% reduction in energy use compared
to codes a decade ago. Their analysis, published
in 2016, forecasts that energy codes will save U.S.
homes and businesses $126 billion between 2012
and 2040. These savings correspond to 841 million
tons of avoided carbon dioxide emissions, which
equate to the annual emissions of 245 coal power
plants.
The new challenge for the design engineer is
advocating for the application of cost-effective
design practices and technologies that minimize
energy consumption and carbon footprint without
compromising the critical environmental parame-
ters of industrial facilities.

HVAC design Figure 2: A model clean room facility

The design of HVAC systems to serve pharma-
ceutical and biotechnology facilities is completely
custom and is uniquely dependent upon the specif-
ic manufacturing process, raw materials and drug
product as well as the project sponsor/client specif-
ic standards and requirements. Some clean rooms
require very strict temperature and humidity con-
trol based on raw material or drug product require-
ments while other clean rooms require high levels
of air containment or air filtration to protect the
product from personnel or vice versa. Some clean
rooms require all of the above as well as active pres-
surization controls.
Therefore, not all clean room facilities are the
same. Each project’s HVAC system requirements are
unique and must be custom engineered in detail to
is used as the basis of this study (approximately 3,600 square feet).
implement energy-saving strategies that align with
the scheme of the facility.
The facility presented in this case study consists
of approximately 3,600 square feet of clean room
space consisting of ISO-7, ISO-8 and common cir-
culation corridor. The study compares four dif-
ferent approaches, which are all common among
engineers and designers for an HVAC system
design of clean room spaces. The study assumes
identically configured central plants serving the
HVAC system for each model and provides the fol-
lowing central utilities for the purpose of this com-
parative analysis:

www.csemag.com consulting-specifying engineer December 2019 • 43

BUILDING SOLUTIONS
CASE STUDY

• An air-cooled chiller with distribution pump CASE 1: 100% outside air unit
to serve a chilled water-cooling coil. A once-through air system that provides 100%
outside air to the clean room environment typi-
• Natural gas-fired steam boiler to serve steam cally is required when the designer wants a sys-
heating and direct steam injection humidifica- tem to serve suites where a biosafety level must
tion requirements. be contained or where segregation is necessary to
prevent cross-contamination between products
• Natural-gas fired hot-water boiler to serve or processes. A once-through system design is
heating hot water requirements of the air usually required as a result of suite pressurization
systems. relationships, dust extraction or fume contain-
ment needs or process equipment requirements.
The four cases evaluated in this study each The design used in this case study consists of
assume that the space will be maintained at 68°F a central station air handling unit with cooling,
plus or minus 2°F and relative humidity is con- heating, dehumidification and humidification
trolled between 30% and 60%. Each air system of capabilities that provides filtered, preconditioned
this study has its own purpose for supporting a outside air directly to the clean room environ-
clean room environment and is described in fur- ment. An exhaust system also has been provid-
ther detail. ed in the analysis to remove air directly from the
Table 1: Fan sizing comparison by system type
Return/exhaust Outside
Supply fan data fan data air
Room(s)
Air system type Room(s) area
served
Motor Motor
Flow rates Flow rates Flow rates
sizes sizes
CASE 1: 100% OUTSIDE AIR SYSTEM DESIGN
3,575 square
100% outside air unit All 13,800 cfm 30 hp 13,800 cfm 10 hp 13,800 cfm
feet
CASE 2: PRIMARY-SECONDARY SYSTEM DESIGN
MUA-1 (primary unit) - - 600 cfm 1 hp 600 cfm 1 hp 600 cfm
Controlled
1,070 square
AHU-1 (secondary unit) nonclassified) 2,150 cfm 3 hp - - -
feet
corridor
AHU-2 (secondary unit) Grade C areas 575 square feet 4,250 cfm 10 hp - - -
1,930 square
AHU-3 (secondary unit) Grade D areas 8,950 cfm 20 hp - - -
feet
CASE 3: RECIRCULATION UNIT WITH ECONOMIZERS
1,070 square 100 to
AHU-1 (unit with economizer) CNC Corridor 2,200 cfm 3 hp 2,200 cfm 2 hp
feet 2,200 cfm
150 to
AHU-2 (unit with economizer) Grade C areas 575 square feet 3,450 cfm 7.5 hp 3,450 cfm 3 hp
3,450 cfm
1,930 square 400 to
AHU-3 (unit with economizer) Grade D areas 8,200 cfm 20 hp 8,200 cfm 7.5 hp
feet 8,200 cfm
CASE 4: FFU WITH MAU SYSTEM DESIGN
MUA-1 (primary unit) - - 3,700 cfm 5 hp 3,700 cfm 5 hp 3,700 cfm
FFU room 1 1,070 square
CNC corridor 2,150 cfm 0.390 kW - - -
(five fan-powered HEPAs) feet
FFU room 2
Grade C airlock 175 square feet 1,025 cfm 0.156 kW - - -
(two fan-powered HEPAs)
FFU room 3 Grade C
400 square feet 2,350 cfm 0.390 kW - - -
(five fan-powered HEPAs) clean room
FFU room 4
Grade D air lock 240 square feet 1,000 cfm 0.156 kW - - -
(two fan-powered HEPAs)
FFU room 5 Grade D 1,690 square
7,050 cfm 1.092 kW - - -
(14 fan-powered HEPAs) Clean room feet

Table 1: This evaluates a traditional HVAC system approach for the design of the clean room suite compared to several
alternative designs that emphasize energy performance optimization and compliance with the latest energy-efficient
building codes. Courtesy: CRB

44 • December 2019 consulting-specifying engineer www.csemag.com

suite or from process equipment within the suite.
The air handler is typically a custom unit with
multirow heating and cooling coils using steam
and chilled water, respectively, for temperature and
humidity control. The fans require higher motor
horsepower ratings to accommodate the necessary
supply airflow rates of the clean room suite(s). This
is due to higher air-change rates inside the clean
rooms. The larger fans need to overcome higher
static pressures from high-efficiency particulate air
and ultralow particulate air filtration.
These types of systems are extremely ener-
gy-intensive and are usually designed to include
provisions for energy recovery to comply with
international codes and ASHRAE standards.

CASE 2: Primary 100% outside air

unit with secondary recirculation units Figure 3: This schematic diagram of the air system design is associated
A primary/secondary air system is a tradition- with case 1 and case 2 of this study. Courtesy: David Korzuch, CRB
al approach for clean room HVAC system design
and consists of a 100% outside air primary unit for
preconditioning makeup air to multiple recircula-
tion-type secondary units. This design allows for a
smaller 100% outside air unit, which provides only
enough air to maintain the ventilation and pressur-
ization requirements of the secondary units.
Most facilities that have multiple clean room
suites designed for multiproduct or campaign pro-
duction use this approach for their HVAC system
design. The secondary units contain smaller coils
and fans that are designed to meet the specific tem-
perature/humidity requirements and air-change
rates of the individual clean room suites.

CASE 3: Recirculation units with

enthalpy-based economizers
Dedicated, recirculation-type units with mod-
ulating (0% to 100%) enthalpy-based outdoor air
economizers are being used for the clean room
environment due to the advancement of direct dig-
ital control technology. HVAC systems for clean
room environments operate best under constant
conditions. Once the designer introduces modulat-
ing technologies for energy optimization, such as
the dampers required of an economizer, the clean Figure 4: A schematic diagram of the air system design is associated
room suite risks controllability of pressurization with case 3 and case 4 of this study. Courtesy: David Korzuch, CRB
and temperature/humidity excursions.
However, due to the advancement of DDC tech-
nology for HVAC controls, systems are now pro- CASE 4: Fan-filter modules with
grammed with complex algorithms capable of a makeup air system
maintaining temperature, humidity and pressurization Fan-powered HEPA filter modules are very
while compensating for modulating sequences relat- popular in clean room environments and use ener-
ed to fan speed, temperature reset strategy and outside gy-efficient electronically commutated motors
air control. If the designer must meet more strin- to maintain the air-change requirements of the
gent energy conservation goals, such as U.S. Green suites. The once-through air system for this con-
Building Council LEED or more recent versions of figuration, which is more commonly referred to
ASHRAE 90.1, then economizers may be considered as a makeup air unit, would provide precondi-
mandatory in the clean room’s HVAC system. tioned outside air to the fan-powered HEPA mod-

www.csemag.com consulting-specifying engineer December 2019 • 45

 BUILDING SOLUTIONS
CASE STUDY

ules. This design allows for a MAU that provides
enough outdoor air to maintain the ventilation,
pressurization and cooling air requirements of the
clean room suite.
Fan-powered HEPA modules would either be
directly ducted or pull air from a common dis-
tribution plenum to serve the suites. The MAU
would provide enough air to overcome any fan
It also should be noted that these types of sys-
tems are notorious for having balancing issues
and it may be difficult to meet pressurization
requirements if plenums are not properly sealed
or balanced.
Study results, achieving
energy efficiency

‘
This study produced comparative energy mod-
eling calculations of four different air-system
If the designer must meet more design approaches and how they relate to a model
clean room environment. Modeling was conduct-
stringent energy conservation goals, ed using a third-party computer-based program to
perform an 8,760-hour energy simulation to deter-
then fan-powered HEPA modules with a mine the energy consumption of each case.
The study has concluded that airflow rates
MAU should be considered for the design remain relatively constant among different design
strategies due to the mandated air change require-

’
of a clean room’s HVAC system. ments of the facility; however, fan motor efficien-
cy and air delivery method for conditioning the
clean room environment is very different in each
motor heat gain and other sensible heat gains model and proves to be where the majority of ener-
within the space. If spaces have a larger latent gy usage occurs within each design strategy.
heat gain (typically from a wet process), then Fan energy and space conditioning typically
this HVAC system design is not ideal considering account for about 47% of energy use in pharma-
dehumidification is provided by the MAU and is ceutical manufacturing facilities. Therefore, even
not directly controlled for each suite. small reductions in the required air-change rates
If the designer must meet more stringent energy can garner large energy-saving opportunities over
conservation goals, such as LEED or more recent the annual energy usage profile of the facility.
versions of ASHRAE 90.1, then fan-powered HEPA As shown in Table 1, each system’s total supply
modules with a MAU should be considered for the flow rate is relatively equivalent; however, varying
design of a clean room’s HVAC system. the air delivery and conditioning methods across
each case presents opportunities for energy-con-
Table 2: Annual cost analysis scious design. The model shows that case No. 4
CASE 1 CASE 2 CASE 3 CASE 4
provides the greatest amount of energy savings
due to the extremely efficient ECM fan motors that
HVAC COMPONENT ANNUAL COSTS maintain the required air-change rates within the
spaces.
Air system fans $26,483 $21,465 $24,729 $7,299 The MAU only requires two 5-horsepower fans
to deliver the optimal amount of outside air to the
Cooling $24,598 $8,477 $3,224 $10,733
clean room environment for space conditioning;
Heating $29,103 $1,818 $964 $10,246 the designer must be careful to properly size the
MAU for conditioning the heat gains and heat loss-
HVAC subtotal $80,184 $31,761 $28,917 $28,279 es in the spaces to ensure space temperature and
relative humidity can be maintained. The designer
NON-HVAC COMPONENT ANNUAL COSTS
must also account for pressurization air gains and
Lights $1,098 $1,098 $1,098 $1,098 losses into the clean room suites, as the MAU and
associated exhaust fan will need to maintain the
Electric equipment $4,814 $4,814 $4,814 $4,814 required pressurization of the facility, which hasn’t
Non-HVAC subtotal $5,912 $5,912 $5,912 $5,912
been factored into this analysis.
It should be noted that this type of system
GRAND TOTAL $86,096 $37,672 $34,829 $34,191 design doesn’t work well for large clean room areas
with lots of separate rooms at different pressuriza-
Table 2: The case study presents 12 months of estimated energy per- tion levels. In addition, this type of design could
formance data and garnered energy use on a dollar-per-square-foot require more maintenance due to a large quantity
basis that can be used as a conceptual tool by designers and engi- of fan filter units.
neers to aid in the development of more energy-efficient clean room The second alternative in pursuit of a more
facilities. Courtesy: CRB energy-conscious HVAC design is a traditional

46 • December 2019 consulting-specifying engineer www.csemag.com

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BUILDING SOLUTIONS
CASE STUDY

Table 3: Annual cost analysis use reduces significantly when considering the use
per square foot by case of economizers of case No. 3 compared with the
primary/secondary system of case No. 2; however,
CASE 1 CASE 2 CASE 3 CASE 4 the designer must be aware that the facility’s pres-
HVAC COMPONENT ANNUAL COSTS PER SQUARE FOOT
surization strategy could be jeopardized with the
introduction of air-side economizers. Water-side
Air system fans $7.408 $6.004 $6.917 $2.042 economizers may be a better alternative to comply
with energy code and are typically preferred over
Cooling $6.881 $2.371 $0.902 $3.002
air-side economizers when designing clean room
Heating $8.141 $0.509 $0.270 $2.866 HVAC systems.
Twelve months of energy data based on the
HVAC subtotal $22.429 $8.884 $8.089 $7.910 simulated energy model were compiled and the
estimated energy use of each HVAC system design
NON-HVAC COMPONENT ANNUAL COSTS PER SQUARE FOOT are summarized in Tables 2 and 3. Table 2 shows
Lights $0.307 $0.307 $0.307 $0.307 component costs based on an average electric rate
of $0.973 kilowatt hours and an average natural
Electric
$1.347 $1.347 $1.347 $1.347 gas rate of $10.13/mille cubic feet.
equipment
Table 3 summarizes the component costs in an
Non-HVAC estimated dollar per square foot metric that can
$1.654 $1.654 $1.654 $1.654
subtotal be extrapolated and used by designers looking to
baseline the annual energy use of a clean room
GRAND TOTAL $24.083 $10.538 $9.742 $9.564
facility based on HVAC system type.

Table 3: This summarizes the component costs in an estimated dollar
per square foot metric that can be extrapolated and used by design-
ers looking to baseline the annual energy use of a clean room facility
based on HVAC system type. Courtesy: CRB
Best approach and recommendations
As with all building design, energy efficien-
cy needs to be evaluated at the beginning of the
design process. The approach should be a col-
laborative one that involves the design and con-

‘
struction teams. Thoughtful consideration should
be applied to developing key building attributes.
A methodical approach to the overall This needs to be discussed early in the design pro-
cess due to the major impact they can have on the
building design can have a significant overall building energy consumption and more
specifically, the HVAC systems.
A methodical approach to the overall building
impact on reducing the HVAC loads and design can have a significant impact on reducing
the HVAC loads and the overall energy consump-

’
the overall energy consumption.
primary and secondary air system strategy, which
is identified as case No. 2. The designer using this
system must ensure the design meets the latest ver-
sion of energy code, which may now require alter-
native design methods, such as HVAC systems with
0% to 100% economizer controls, to be considered.
If economizers are considered for a clean room
facility, the designer would need to carefully iden-
tify a design method for managing the economizer
system functionality and would need to provide a
means to exhaust the necessary airflow from the
clean room during that mode of operation. There-
fore, the designer must be aware that this design
strategy would likely result in more controls and
equipment to achieve the economizer function.
Case No. 3 shows the annual energy use of
three air handling systems with integrated econ-
omizers. The cost of heating and cooling energy
tion. Slight changes in key attributes, such as glaz-
ing types and amounts, can be easily be modeled
in various design platforms showing real-time
impact of the design decisions.
Another key aspect for the design process is
defining meaningful and measurable energy per-
formance benchmarks and setting project-specific
goals. With clearly defined goals, the design team
can develop energy-saving strategies for the vari-
ous building systems.
When approaching HVAC design for a clean
room application, the first step is documenting
key performance parameters of the critical envi-
ronment, such as cleanliness levels, temperature,
humidity, pressurization and air changes per hour.
The definition of these requirements is a vital ini-
tial step in the HVAC design process as it has the
largest impact on system sizing and configuration
and the overall complexity of the facility.
Often, the owners of the facility have estab-
lished ACH that are associated with their unit

48 • December 2019 consulting-specifying engineer www.csemag.com

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input #13 at www.csemag.com/information
BUILDING SOLUTIONS
CASE STUDY

operations and the required cleanliness level.
Advocating for a risk-based approach and chal-
lenging established practices will be the required
paradigm shift for the design team moving for-
ward. Without designers advocating for lower air-
change rates, many owners will remain averse to
changing their guidelines despite energy and cost
savings due to perceived risk.
In addition, the design teams must challenge
common misconceptions associated in the indus-
try with respect to the zoning of HVAC systems
and the effectiveness of proper filtration. Unless
there is potential for free-floating viruses, pushing
for increased unit segregation with HVAC systems
should only be considered in extreme situations.
Maintaining the status quo, using high ACH rates
and increasing the complexity of HVAC systems
to mitigate perceived risk directly correlates to
increases in initial facility cost, ongoing operational
costs and a carbon-intensive facility.
Another key aspect for consideration when
designing HVAC systems for clean rooms, although
not the intent of this article, is understanding the
impact of hazardous raw materials, such as flam-
mable, combustible liquids and potent compounds.
As a designer, it is vital to understand the quantities
and types of materials used in the process, as they
have design and code implications related to person-
nel safety, building safety and environmental impact.
Building codes, fire codes and adopted standards
will dictate the design of facilities using such mate-
rials in their processes. In general, more stringent
ventilation requirements will be the result of using
these materials and will take precedence over some
of the energy code requirements due to the impact
on life safety.
A risk-based approach combined with analyti-
cal and economical models can assist the design
team in determining the appropriate HVAC sys-
tem design that not only meets the critical design
requirements of a facility, but also achieves an ener-
gy-efficient and code-compliant design. cse
David B. Korzuch Jr. is a mechanical engineer at
CRB, focused on HVAC and mechanical system
design for current good manufacturing practice
manufacturing facilities, laboratories and central
utility plants for the biotech and pharmaceutical
industries.
Christopher J. Barbieri is a project manager and
the mechanical discipline lead at CRB, focused on
discipline specific and cross-functional strategic ini-
tiatives and tactical tasks for the company.

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www.csemag.com consulting-specifying engineer December 2019 • 51

ENGINEERING INSIGHTS
MEP ROUNDTABLE
Lab, research facility design
Learn tips on how to design labs and research facilities —
some of the most high-tech buildings around
CSE: What’s the biggest trend
in laboratory and research facility
projects?
Kelley Cramm: Probably the biggest
trend we’re seeing is an increased move
toward open, modular laboratories. Open,
modular labs accommodate changing
research over time and allow flexibility for
new equipment, researchers and evolving
technology. They also improve collabora-
tion between researchers from multiple
disciplines.
To improve flexibility, many labs are
using pre-wired and piped modular case-
work with “plug and play” capability. The
utilities are supplied to a ceiling panel or
overhead service carrier and connected to
the casework from there. Utilities can be
distributed to every module with servic-
es not initially needed valved and capped
above the ceiling or in the overhead ser-
vice carrier. This allows flexibility for
changing needs with minimal disruption.
Bryan Floth: The biggest trend we’re
seeing within laboratory and research
facility projects is designing for flexibil-
ity. Advances in scientific research are
accelerating in all areas. This has created
unprecedented demand for new and more
sophisticated facilities that can accommo-
date state-of-the-art technology. The cost
to remodel facilities at the same rate can
be substantial. It’s forcing a lot of plan-
ning and designing to be more generic
and flexible, to better react to shifts in the
industry.
Kelley Cramm, PE,
LEED AP BD+C
Associate/Mechanical
Technical Leader
Henderson Engineers
Kansas City
52 • December 2019 consulting-specifying engineer
George Isherwood: The biggest
trend we are seeing is working through
the balance of energy efficiency with
equipment costs for the energy perfor-
mance. Most, if not all, of our clients
have “green” plans until they realize the
increase in equipment costs.
Adam Judge: Most new facilities
we have seen in the past few years have
included large, shared open lab areas that
catalyze collaboration and conversations
among researchers. This collaboration
encouraging concept is even spreading
outside the laboratory spaces and into the
common area and circulation spaces, such
as open stairways and atria creating vis-
ibility between different floors, areas or
departments. Often the primary inves-
tigators are not all known at the time of
design, so most laboratory spaces need to
be designed to be flexible for adaptation
to future needs.
Iain Siery: Generally, I think advanced
therapeutic medicinal products research
and development are on the rise. This is
particularly true in Philadelphia, where
several key advancements have been
made that are driving significant attention
to this space within life sciences. These
projects have different drivers and require
specific expertise to create facilities that
support clients in this field.
David Wilson: Providing flexibility in
the design of laboratory spaces and utili-
ties to allow for modifications to the lab-
oratory spaces on an individual basis as
research changes or changes in research-
Bryan Floth,
LEED AP, AIA
Senior Project
Manager
Burns & McDonnell
Kansas City, Mo.
ers occur. The advancement in technolo-
gy and funding availability is often driving
changes in the type of research being per-
formed at any given time and changes
appear to be occurring more rapidly than
in the past.
CSE: What future trends should
engineers expect?
Isherwood: Integration of the controls
throughout the projects are starting to
gain momentum in the industry. We are
starting to see multiple trades starting to
work together to accomplish a more effi-
cient system. Window shade controls are
interfacing with lights that are interfac-
ing with temperature controls. There have
been several challenges with integrating
these systems and allowing them to not
only read into their system but adjust set-
points as well.
Siery: I am expecting continued and
increasing pressure on projects due to
overall cost. Today, we explore numer-
ous approaches to managing the cost of
projects. This includes saving time by
integrating the design and construction
process, as well as design approaches that
directly manage cost such a target value
design/delivery. Finding the right balance
of flexibility, speed of delivery and cost
has been increasingly central to the suc-
cess of research laboratory projects. These
aspects can be at odds in many cases. In
particular within the life sciences R&D
industry, speed to market is becoming
George
Isherwood, PE
Vice President, Health
Care/Laboratory Group
Leader
Peter Basso Associ-
ates Inc.
Troy, Mich.
www.csemag.com
more critical, so solutions to these chal-
lenges must continue to evolve.
Floth: Speed to market is critical for
lab and research facility projects today
and will continue to be critical in the
future. There is a growing expectation for
buildings to be designed and built fast-
er. Schedule, productivity and innova-
tion are always top of mind. Any scenario
in which the research associated with a
lot of these facilities is delayed can delay
the ability of the research organization to
meet market deadlines.
We’re incorporating lean principles
and management approaches into the
process to help meet expectations, deliv-
ering a high-quality, on-schedule proj-
ect. The purpose of the lean management
approach has two central components: a
fully integrated team approach to design
and delivery from the early stages of a
project, and the incorporation of lean
principles, processes and tools to attack
the sources of waste. Together these two
concepts can translate to big advantages
for an owner.
Cramm: I think an increased demand Figure 1: The University of South Florida Health Morsani College and Heart
for sustainability and reduced carbon foot- Institute is a new research and teaching facility designed to provide students
print will be the overarching trend. Labora- with a high-tech learning environment, a with an advanced research facility to
tories consume massive amounts of energy explore new heart disease treatments. Features include clinical teaching labo-
and water. This will drive changes to the ratories, large lecture halls, smaller classrooms and teaching labs and flexible
way we design labs and to the way users space. Courtesy: TLC Engineering Solutions
operate in the lab. We will see an increase
in the use of energy recovery, high-perfor-
mance fume hoods, occupancy-based set- CSE: What types of challenges containment to protect personnel. This
backs for lighting and ventilation, wind do you encounter for these types drives us to fully exhausted laborato-
responsive exhaust fan modulation and of projects that you might not face ries with systems that need to run 24/7.
improved ventilation effectiveness at lower on other types of structures? Another difference is the increased use of
air change rates. Users will be pushed to gases that create a flammability or asphyx-
use more efficient lab equipment — espe- Cramm: Density of power is one key iant hazard. These require specialized sys-
cially freezers — and to shut down lab difference. We’re seeing an increased use tems to mitigate the risk to human life and
equipment when not in use. of ultralow-temperature freezers and health.
Judge: I expect future projects to analytical instruments that come with Wilson: The challenge is designing
continue the trend of flexibility. This computers and printers attached. This utility and utility systems to be generic
may mean flexibility to adapt the design equipment demands more power than in nature but customized on a lab-by-lab
to different floor plan layouts, differ- most other occupancies. Spare circuits basis to meet the current research needs
ent equipment or other environmental to accommodate future growth and new of each individual space. Providing utility
requirements as researchers are recruited instruments are critical. Another key dif- systems for future use in each laboratory
during the design phase, during the con- ference is the hazards associated with may add additional upfront cost when ini-
struction phase or post-occupancy. laboratories and the resulting need for tially constructing the building but allows

Adam Judge, PE Iain Siery, PE David Wilson, PE,

Associate/Mechanical Senior Mechanical LEED AP
Project Engineer Engineer Senior Engineer
TLC Engineering CRB Dewberry
Solutions Philadelphia Raleigh, N.C.
Tampa, Fla.

www.csemag.com consulting-specifying engineer December 2019 • 53

 ENGINEERING INSIGHTS
MEP ROUNDTABLE
for modifications to each laboratory on an individual basis
without affecting adjacent spaces and associated research
occurring in each space. Long-term research can be lost if dis-
ruptions to utility systems occurs due to shutdowns required
to modify utility systems.
Floth: The biggest challenge is the complexity of these
projects. Science facilities require design that integrates spe-
cialty building systems, utilities and equipment with the
human element of a pleasant working environment. Each
laboratory, clean room or research space has unique envi-
ronmental requirements, but all have a focus on efficiency,
flexibility and safety at their core. Layered on top of that,
many facilities hope to attract grants and achieve other
unique certifications, requiring additional guidelines beyond
making the building code compliant.
Judge: Building in sufficient flexibility for changes in lab-
oratory spaces can be much more challenging than in other
types of buildings. Because laboratory equipment can often
vary widely in utility requirements, much more flexibili-
ty must be built in. In addition, with the governing energy
efficiency codes become more stringent, laboratory facility
design often requires thinking out of the box to not only meet
energy code requirements, but often beat them to meet the
sustainability goals of the project.
Isherwood: Most buildings are built with the intent of
keeping the occupants comfortable. People working in offices
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and students in classrooms are more productive when com-
fortable. Laboratories introduce harmful elements into that
environment that can affect both the safety of occupants and
the surrounding areas. The management of chemicals or other
harmful elements is what makes laboratories unique.
Siery: Specific design challenges include creating inspira-
tional environments that balance scalable infrastructure, flex-
ible casework and utility distribution, constructability and
project cost and schedule drivers.
CSE: What are engineers doing to ensure such proj-
ects meet challenges associated with emerging tech-
nologies?
Cramm: Innovation and creativity are key to successful
laboratory design. The understanding that what’s happening
in the lab today will not be what’s happening in the future
is critical. Engineers should never design a “purpose built”
laboratory. All systems and utilities need to be designed to
be flexible enough to adapt to future changes in laboratory
equipment and evolving research. This means planning for
systems to be expandable and designing services using a mod-
ular planning approach. It also means sizing ducts and chases
to allow for additional airflow and providing plenty of spare
electrical circuits in panelboards to accommodate the inevi-
table addition of laboratory equipment.
Floth: Having an integrated team is a game changer when
it comes to delivering facilities that meet challenges associated
with rapidly evolving technologies. Long before design begins,
our architects, engineers, planners, environmental specialists
and construction professionals work with clients to establish
requirements. This gets all stakeholders and involved parties on
the same page from day one. By interviewing lab stakeholders —
from director to technicians — our designers help shape facil-
ities’ physical and aesthetic goals and objectives. We carefully
analyze traffic flow, space needs, type and number of analyses,
standard testing methods, lab safety and equipment and regula-
tory requirements — a crucial first step in turning the vision of a
facility into steel, concrete and glass, utilities and systems.
Judge: Engineers need to get as good of an understanding
as possible of potential future plans for the laboratory spac-
es. Considerations must be taken regarding ventilation, cool-
ing and exhaust, power requirements — including emergency
generator or uninterruptible power supply standby power —
water requirements, data requirements and chemical quantity
limitations of potential future equipment and processes. The
design team must inform the owner of the assumptions and
limitations they must live with.
Siery: I am seeing significant emphasis on integrated solu-
tions that bring the design and construction experts togeth-
er (design-build and design-assist) to improve overall project
schedule. Then these teams can more effectively leverage bud-
get management strategies such as target value delivery to
ensure the project is successful.
CSE: Tell us about a recent project you’ve worked
on that’s innovative, large-scale or otherwise note-
worthy.
54  December 2019 CONSULTING-SPECIFYING ENGINEER
 Redefine
Floth: One recent project our team
was selected for is the NextGen Precision
Health Institute at the University of Mis-
souri. We’re providing architectural, master
Flexibility
planning and engineering design services
for the $220.8 million research facility. The
facility will aim to bring together indus-
try partners; engineering, medicine and
veterinary science students; and the fed-
eral government to pursue a collaborative
approach to personalized health care, sup-
ported by advanced technology. Construc-
tion for the 275,000-square-foot facility is
expected to be completed in October 2021.
Judge: Construction is nearing com-
pletion of the new 395,000-square-foot,
13-story University of South Florida Mor-
sani College of Medicine and Heart Institute
in the newly designated Water Street district
in downtown Tampa, Fla. TLC Engineering
Solutions teamed with architects HOK and
builder Skanska for this design-build project
with an estimated construction cost of $173
million. The project includes four classroom The WaterFurnace WC Modular Scroll Chiller is the
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M More
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ROUNDTABLE
GO ONLINE
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