Case Study: Hospital Emergency Department

MarCraft TruCustom HVAC Systems Delivered A Plug-N-Play Rooftop Mechanical Room AHU in Record Time


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Why MarCraft TRU-CUSTOM? Delnor Hospital needed a replacement HVAC system for their existing packaged air handler serving the waiting area of an operational emergency department. Due to limited mechanical space available indoors, a custom HVAC System was needed to meet the requirements for the hospital. Temporary heating, cooling, and ventilation was provided while the HVAC system was down.

The mechanical engineer required a system that had a service vestibule to locate chilled and hot water piping, variable frequency drives, temperature controls, single-point power connection, and a steam generating humidifier. The system also had to be lightweight to keep building structural steel modification to a minimum. A packaged HVAC air handler could not meet these requirements, and MarCraft Custom HVAC Systems delivered.

Since a temporary HVAC System was currently conditioning the hospital, MarCraft needed to meet a logistics deadline for getting equipment on site and on time.

MarCraft TOTAL Solution MarCraft Custom HVAC Systems designed an all aluminum construction air handler for weight savings because the equipment would be lifted/mounted to the roof and the structural steel on the building was a concern. Final system components included: 4” thick double wall housing with foam insulation; Return fan; mixing box; pre-filter; hot water coil; humidifier; chilled water coil; UVC lights; dual supply fans; final filter; vestibule electrical unit heater; exterior and interior lighting; exterior convenience electrical outlets; stair and platform.

The HVAC system needed to meet the tight shipping deadline, and needed to be sectionalized for logistic purposes. The equipment arrived on time at the jobsite and was delivered in four sections and lifted/set-up on the same day. Assembly of the equipment at the jobsite was completed within a short two-week timeframe for installation, utility connections, start-up and commissioning.

Results The client was extremely satisfied with the aluminum construction for weight savings, components, and materials used to meet their custom requirements. Most importantly, the logistics coordination was a key factor in delivering the equipment on time and on budget, as MarCraft Custom HVAC Systems exceeded expectations

THE DELNOR HOSPITAL MARCRAFT TRUCUSTOM HVAC SYSTEM INCLUDED:

CONSTRUCTION

  • Total CFM is 20,400, min. OA 7140 CFM, return air 17,200 CFM
  • All aluminum construction. Exterior was painted with special color requested by customer.
  • Interior designed as washdown capable. 4” thick walls/roof w/ fiberglass insulation. Aluminum base with polyurethane foam insulation. Unit weight and foot-print was of major concern on project because of space & structural limitations of building roof. RTU was designed in four sections.
  • 4” thick walls/roof w/ fiberglass insulation.
  • Aluminum base with polyurethane foam insulation.
  • Unit weight and foot-print was of major concern on project because of space & structural limitations of building roof. RTU was designed in four sections.
  • Unit weight and foot-print was of major concern on project because of space & structural limitations of building roof. RTU was designed in four sections.

Services

  • Electrical and pneumatic component intergrity testing including hi-pot electrical circuit testing.
  • Fan assembly testing and balancing
  • Coil leak test
  • Piping leak test – this is a leak verification test before shipping to verify system integrity. Test will be completed on-site by others after shipping and re-assembly.
  • Unit casing air leakage & deflection testing (optional)

  • Air-flow testing (optional)

COMPONENTS

  • Cooling coils utilizing 20% propylene glycol/water mixure, 0.035” thick copper tubes, 0.016” AL fins, 304 SS casing, connections red brass w/ grooved victaulic fitting, aluminum drain sunken drain pan with SS expanded metal walk-on grating, aluminum slide racks included.
  • Hot water heating coils, 0.035” thick copper tubes, 0.016” AL fins, connections red brass w/ MPT fitting, aluminum slide racks
  • Supply fan array with two direct drive stackable cube type 12 air foil blade plenum fans suitable for use with VFD. Includes piezo. rings for air flow measuring capability, grounding rings, TEFC motors & inlet screens. Fans are self isolated. Cube type fans provide ease of installation in fan array configuration and also provide superior sound control.
  • Return fan assembly – Vertically mounted plenum ran – 12 air foil blades, protective enclosure, piezo. Rings for air flow measuring capability, grounding rings, & TEFC motor. Includes structural aluminum vibration isolation base with seismic type 2” deflection isolators.
  • Dispersion grid type humidifier with steam generator supplied by others for installation by MarCraft. Includes sunken aluminum drain pan with SS expanded metal walk-on grating.
  • Service vestibule with unit heater including circulation dampers & modulating actuators, access doors included in floor for access to roof curb.
  • UVC lighting downstream of cooling coils, wired in conduit to J-Box in Service vestibule
  • Convenience circuit – single point 120V that provides vapor-tight incandescent light fixtures with compact fluorescent bulbs, GFI protected receptacles, and light switches, NEMA-1 J-Box for 120V connection by others.
  • Fan motors wired Flex/EMT conduit to non-fused safety disconnects and VFDs w/ bypass.
  • All other components wired in EMT conduit to fused disconnects.
  • Power distribution panel w/ indication and control circuit, 460/3/60 connection provided by others.
  • Unit controls, control panels, and associated components provided by others for installation by MarCraft. Unit actuators provided and installed by MarCraft.
  • Factory piping for humidifier and coils provided and installed by MarCraft. Piping insulation provided by others on-site after piping verification testing.
  • Service platform with rails and steps for ease of access to service vestibule. Ships fully welded in single piece for installation on roof by others.

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