One of the nation’s largest aerospace firms planned to expand and modernize existing capabilities at an occupied research and development facility in southern California. Xcel Mechanical Systems, based in Gardena, CA, was hired to design and build the mechanical, plumbing and process piping elements of the new project. To minimize risk and maximize labor efficiency Read more
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One of the nation’s largest aerospace firms planned to expand and modernize existing capabilities at an occupied research and development facility in southern California. Xcel Mechanical Systems, based in Gardena, CA, was hired to design and build the mechanical, plumbing and process piping elements of the new project. To minimize risk and maximize labor efficiency, the Xcel team selected NIBCO® Press fittings and valves as a smart solution for the multi-phase project.
“Leveraging press technology mitigates the inherent risks of working with open flame within an occupied space,” said Jason Gordon, Xcel Mechanical’s vice president of operations. “We chose NIBCO Press for this job for multiple reasons, including safety, time and labor savings, and aesthetics,” said Gordon, whose firm has been a preferred design-build mechanical contractor on the sprawling campus for more than two decades. “NIBCO is a proven brand name in our industry. That’s important to us because the products we select are a reflection on our company.”
After four carefully planned construction phases, three and a half years of steady and precise work, the $8 million HVAC, plumbing and piping elements of the estimated $50 million laboratory modernization project are nearing completion.
The total renovation project included remodeling existing labs located on the ground floor of a three-story, 1960s-era research and manufacturing facility; labs which must be constantly redesigned and reconfigured to meet the specific requirements of each new contract award. The owner’s primary goal was to convert the subdivided lab space into a large open floor plan, creating the opportunity to build-out a modern, flexible and scalable “factory of the future” that would maximize the total available 160,000-square feet of lab and manufacturing space and 57,000-square feet of office space.
The building was stripped down to concrete on all four sides, exposing what was left: columns, high ceilings, and slabs. The original building design included old stanchion supports with piping and electrical systems running up from the floor. To free up valuable floor space, the new design features steel overhead utility racks that now run 500-600’ feet across the exposed ceiling for a nice clean application. Major mechanical and plumbing systems were removed and redesigned to align with the new design.
Project team members, from left: Wes Whittle (Piping and Plumbing Superintendent); Foreman Shawn Gibson (Pipefitter, Welder); Jason Gordon (VP of Operations); Foreman Ray Adams (Plumber, Pipefitter); Tim Brown (Service Technician); Steve Prisk, CSHO, ASH (Safety Director).
The Safety Factor
In this facility, the mains on the overhead utility distribution racks are sized 2” down to ¾”. Separately, the HVAC system has chilled water and heating hot water lines measuring up to 4” in diameter. Some of those lines drop down from a chilled water system located on the roof that serves a newly installed air handler.
“Typically, we would use steel for those 4” lines,” Gordon said. “But since the piping ran down an existing shaft, there were safety concerns around welding or grooving the 4” steel. And then there was the weight factor and what would be required to run steel pipe down that shaft versus copper,” he said.
“For these reasons, my foremen advocated for the additional material spend on copper. Obviously, the material cost is considerably more but we felt the safety benefits and labor savings would offset it,” Gordon said. “We are a strong believer in getting perspective from our foremen. If they support the plan, believe in the products they are installing, and it makes sense financially, then it’s a win-win.”
Gordon said using NIBCO Press on the project also meant not having to go through the facility’s Hot Work permitting process which typically adds time to any project. “The customer liked that the NIBCO product removed a certain level of risk, and also the smell of soldering and flux from an operational lab environment,” he said. “So, in the end, our customer was happy. Our safety team was happy. And our field personnel were happy.”
Labor Savings is Big
NIBCO Press is easy to install which helps reduce labor costs while keeping projects on schedule. “Material is material, but labor is what makes or breaks a job,” Gordon said. The project’s process piping system consists of three copper lines, one each for compressed air, nitrogen, and industrial vacuum systems. Each run is 400-500’ long and includes multiple connection points. Gordon said the press product made working in smaller areas and also making multiple connections overhead much easier from both a safety and labor efficiency perspective. “We fabricated a fair amount of material used in this job, but with a multitude of small overhead connection points located 6-12’ apart along these lengthy runs, the copper press solution was key. We saved a minimum of 30-40% on labor on some parts of this job, and significantly more on other parts,” he said.
Minimizing System Downtime
Through the life of the project, the ongoing challenge was to build safely around the 100-200 employees who were working in the lab areas. The project’s four-phase approach called for temporarily relocating employee teams into other parts of the facility while completing construction one section at a time. “Using NIBCO Press not only reduced labor time, but it shortened shutdown periods, allowing us to get the building back online sooner.”
Looking Good
Although functionality and flexibility played an important role in modernizing this facility, creating a visually appealing space was also a consideration, Gordon said. “Aesthetically the NIBCO Press product is a good-looking product and a clean application overall,” he said. “For nitrogen systems, we would typically purge and braze, and afterward the copper is oxidized. When we install press, the copper looks brand new. It’s a good look.”
Smart Solution
As the project nears completion, Xcel Mechanical will continue to use NIBCO Press systems to ensure their reputation for high quality and good workmanship is maintained. Press is easy to install and the labor cost savings generated cannot be understated. The proven performance of Press makes it a smart solution for every job.
For more information, visit www.NIBCO.com or contact Sally Boyer, manager of marketing communications, at boyers@nibco.com.
It doesn’t seem so long ago we were fending off the “green” movement that was being force-fed into the vocab of working contractors. From green building to green technology, greenwashing was so prevalent that really the only “green” contractors were concerned with was the one they were chasing every day—a profit. But alas, a new Read more
It doesn’t seem so long ago we were fending off the “green” movement that was being force-fed into the vocab of working contractors. From green building to green technology, greenwashing was so prevalent that really the only “green” contractors were concerned with was the one they were chasing every day—a profit.
But alas, a new word has dominated the marketing lexicon—“smart.” Smart cars, smart phones, smart homes and yes, even smart pumps. “The problem is they’re not that smart,” says John Barba, contractor training manager, Taco Comfort Systems. “I’ve heard people who you’d think would know better say idiotic stuff like ‘these pumps do the thinking for you,’ and ‘they take the thinking out of it,’” says Barba.
Image Credit: Noven; Bethesda.net
How about giving credit to the users who actually interact with such devices? “The thing that separates the professional from the DIY’er or the handyman is his or her ability to think and their understanding of systems. That’s why people hire professionals, and that’s why our profession is so valuable. When it comes to systems and components, the professional is the smart one,” says Barba
“The professional knows what he’s holding in his hands, why he’s using it and what impact it’s going to have on the overall system performance. There’s not a pump made that can replace what the pro knows. The machines haven’t taken over yet,” continues Barba.
Intelligent Systems
If the integration or connectivity of disparate components to a holistic, communicative system is considered smart, then I’m buying in. Why not just say that in the first place? Because it’s not market-y, and it’s too long for a tagline. Okay, then the evolution of homebuilding can be categorized as being smart or intelligent because the integration of, say, lighting, security, home entertainment, etc., can be accessed from the convenience of your smart phone (more on that later). But I’d say that is more a matter or convenience than smarts.
In fact, as part of these communicative devices, perhaps on a broader, commercial stage, we are witnessing new phrases popping up such as the Internet of Things (IoT). According to Sokwoo Rhee, former associate director of the Cyber-Physical Systems Program at the National Institute of Standards and Technology (NIST) from 2014 to 2021, IoT can be described as the advancements in sensors and communication technologies that enable us to collect data which was not previously practical; the explosive increase of the amount of collected data enabled us to perform analytics which was not previously practical or meaningful; and the advancements in data analytics that will enable us to better control and optimize the systems to benefit our daily life. Again, I can buy into that.
Remember when cell phones were labeled smart phones? I think they still are. It’s 2007 and my fancy handheld device can make calls and perform functions as a computer. Well guess what? Today, they are just considered phones. And, if they don’t perform almost any function you can think of, well, then perhaps they are just dumb.
And, oh yeah, what makes a smart car? Good gas mileage? Actually, the term Smart Car came from a venture between watchmaker Swatch and Mercedes-Benz, with Smart standing for Swatch Mercedes Art, a branding stroke of genius. Its small stature was designed for city driving with big gas savings and easy maneuverability, with not-so-good safety ratings, I’d imagine. Debuting in the U.S. in 2008, last I read, it was discontinued in 2019.
And back to those smart, magical pumps? “The only word I hate more than ‘smart’ is ‘magic,’” says Barba. “Anyone who says something like that really doesn’t know how ECM circulators really work, or how they interact with systems. No matter how ‘smart’ people claim these things are, you can’t get away from the fundamentals of circulators. These things have performance—or ‘control’ curves—and the system still has a system curve,” says Barba.
According to Barba, there’s no such thing as magic, and the only circulator that can even come remotely close to sizing itself is the Taco VT2218—it’s a Delta-T circulator and varies its speed to maintain a fixed delta-T in the system.
“And I don’t care how many lights and buttons you put on the circulator, you can’t change the fact that when you have a fixed performance curve—as every Delta-P variable speed circulator has—the system has to work where the system curve intersects the control curve. If it’s a zone valve system, speed and flow will change as zone valves open and close, but it still works on the selected control curve. If it’s a zone pump system, a Delta-P circulator won’t vary its speed because there’s nothing in a zone that would create a change in pressure differential. It goes one speed and that’s it. That’s not what I’d call smart.
“Now, that doesn’t mean you shouldn’t use a Delta-P pump as a zone pump. You should—it’ll do some pretty cool things for you provided it’s set up properly. And for that, you need a smart installer who understands what these circulators do, what they don’t do and how they interact with the system,” says Barba.
“Just because a circulator is variable speed, that doesn’t make it magic. This isn’t Hogwarts and you’re not Harry-freaking-Potter.”
What’s my point in all of this? Dig deeper, educate yourself, rely on your experience and knowledge, and don’t rely on marketing taglines such as Smart or Green to sell you completely on something.
“We get 100% of our business through word-of-mouth. Our customers expect professionalism in our service. And we expect our drain cleaning tools to work first time, every time – no exceptions.” So says Charles “Chuck” Maggiore, owner of Grassroots Plumbing in Perryville, Maryland. “I only put my hard earned money into trustworthy, durable equipment – Read more
“We get 100% of our business through word-of-mouth. Our customers expect professionalism in our service. And we expect our drain cleaning tools to work first time, every time – no exceptions.”
So says Charles “Chuck” Maggiore, owner of Grassroots Plumbing in Perryville, Maryland.
“I only put my hard earned money into trustworthy, durable equipment – tools that handle the toughest jobs, and tools that make satisfied customers.”
And that’s why he’s anchored his growing drain cleaning business in rugged, reliable equipment from General Pipe Cleaners.
Generations of General Users
A third-generation plumbing and drain cleaning pro, Chuck comes by that choice honestly. Both his father and grandfather were strong proponents of General tools. And he’s literally witnessed decades of reliable General performance.
But Chuck is the first in his family who actually owns the business. And with his name on the door, he’s doubly serious about keeping his expanding customer base happy.
His main tool of choice? General’s tough, durable Metro® mid-size drain cleaner.
The popular machine packs the performance, punch, and portability to unclog 3” to 6” diameter lines up to 100 feet long.
Compact, Powerful Package
“We handle a wide range of ‘commercial’ customers – emergency drain cleaning for restaurants, auto body shops, breweries, condos, apartment buildings, even churches,” Chuck says. “And the Metro definitely takes a beating – and handles 90% of my jobs!”
Plumbing, drain cleaning, and maintenance pros love it. With more cleaning power than its predecessor, the Metro now carries 100 feet of 9/16” Flexicore® cable to clear stubborn stoppages in 3” to 4” inside lines. Heavy duty 9/16” cable provides more torque than traditional 1/2” cables offer, yet can clean the same size drain lines.
General’s heavy duty Flexicore cable offers superior kinking resistance and unequalled strength with the right amount of flexibility. It’s so tough that it carries the industry’s best warranty protection – one-year against breakage.
Features Enhance Productivity
To clear tree roots and other tough clogs from 3” to 6” lines, simply switch drums to 75 feet of 5/8” Flexicore cable. To adjust to different cable sizes, just turn a knob atop the feed. No special tools are required.
“The Metro has helped me through lots of tough clogs – like roots,” Chuck agrees. “That little machine has taken care of some really big jobs – including clearing out main lines!”
The Metro’s variable speed Power Cable Feed helps. General’s labor saving feature offers enhanced safety and control through blockages. Users easily guide the cable in and out of the line at up to 20 feet per minute – yet keep hands clean and off spinning cable.
“The feed is awesome,” Chuck beams. “Even my apprentice uses it with ease – and she loves it!”
The Metro is lighter and more compact than other mid-range drain cleaners. Its narrow profile facilitates handling in tight spots, on stairs, and during vehicle loading. The maneuverable machine features a fold-down handle, stair climbers, truck-loading wheel, and tough, lightweight frame on heavy duty 10” wheels for easy transport.
Renting Expands Service Options
Chuck quickly adds that, while the Metro packs plenty of muscle, he occasionally rents General equipment for longer tough jobs. And top of the list is the Speedrooter 92R®.
“It’s a favorite of my dad and grandfather,” He recalls. “In particular, my company uses it on one local franchise restaurant that regularly needs long-distance clog removal.”
The Speedrooter 92R clears stubborn stoppages in 3” to 10” lines. Variable speed cable feed offers raw driving and pulling power for long, tough jobs – feeding and retrieving 3/4” and 5/8” cables at up to 20 feet per minute.
Renting also led to a real bargain when Chuck purchased a used General Metro from a local rental center.
“That was about five years ago,” he continues. “We had rented the Metro before, and knew it’d be a great addition to our equipment.”
Professionalism Counts
Chuck likes tools that produce satisfied customers – and help his young business grow.
“That’s why I prefer General machines over competitive brands,” he adds. “They’re tough, job-proven, and easy to maintain.”
“General’s customer service is stellar, too!” Chuck Maggiore continues. “When I started my business, I called competitors for equipment information, and General’s specialists were, by far, the most professional and helpful.”
“It’s another reason why I’m sticking with General.”
It’s evidently working.
“I’m looking to hire more employees now!” he beams.
To learn more about The Metro, and General’s complete line of rental-tough drain cleaning machines, visit http://www.drainbrain.com/rental or call the Drain Brains at 800-245-6200.
Source Brewing is a destination, a place to enjoy a craft brew in a scenic location. And while you’re there, look overhead – you’ll see some Viega products adding to the décor. Located in Colts Neck, New Jersey, Source Brewing is in a 125-year-old converted barn. In trying to maintain some of the character of Read more
Source Brewing is a destination, a place to enjoy a craft brew in a scenic location. And while you’re there, look overhead – you’ll see some Viega products adding to the décor.
Located in Colts Neck, New Jersey, Source Brewing is in a 125-year-old converted barn. In trying to maintain some of the character of the barn, there are exposed beams.
Matt Fleming, Vice President of All Star Plumbing, knew he’d be running copper and carbon steel lines in the building. He also knew some lines would remain exposed, so he suggested Viega, because of its clean look and for several other beneficial reasons.
“The owners liked the look of it, with the exposed lines and such,” Fleming said. “When this job came up, I thought, ‘Let’s press everything in here and see how it goes.’
The flameless connection of Viega press technology was another benefit, since the crew was working in an old wooden structure. There was nothing to worry about, with no flame needed.
The brewery contains 12 tanks with glycol for chilling, and 2″ ProPress fittings were used on those copper lines. The 2″ carbon steel line feeding steam to three tanks was pressed with MegaPress fittings, and there are ¾″ branches from the tanks also done with MegaPress.
For the gas, a 1½” line equipped with MegaPressG fittings runs to the steam boiler. There’s about 100 feet of 1″ carbon steel line with MegaPressG fittings going to the mechanical room.
Mike Glaser, President of Aqua Solutions, installed the water filtration system for the brewery. Nearly all of his Annihilator Ultra Systems are installed with ProPress, and have been for the past decade. He said he uses Viega, because he knows he can’t beat the product.
“Viega is always consistent,” he said simply. “The fittings don’t break, they are reliable, and we don’t have issues with ProPress.”
“This is the first brewery that we’ve done everything with pressing,” Fleming added. “We’re realizing the time savings and efficiency, plus the lack of leaks. We’re not a big company, but we have five other brewery projects now on the forefront!”
No doubt about it, COVID-19 quickly changed the way we work, and play. Travel and in person visits came to a screeching halt. Professional offices, suppliers, even many working shops closed their doors to visitors. Training in the not to distant past was done, for the most part, in person. Conveniently, most trainers adapted quickly Read more
No doubt about it, COVID-19 quickly changed the way we work, and play. Travel and in person visits came to a screeching halt. Professional offices, suppliers, even many working shops closed their doors to visitors. Training in the not to distant past was done, for the most part, in person. Conveniently, most trainers adapted quickly to offer online training options. Many of the companies in our industry were already familiar with platforms like Go To meeting. This made the switch to virtual training fairly easy for those trainers.
Some trainers I met through the ESCO group devised hybrid virtual training events. With a few cameras, one that would follow you around a room they kept the hands on training available also.
An instructor in front of a piece of equipment would be led through the troubleshooting in real time, clever and almost like being there.
The question remains, what happens going forward in the training world. In some cases offices that made the change to virtual workspaces plan on staying that way. In some larger cities’ that has created office space vacancies and those building owners are scrambling to repurpose those spaces to get the rent rolling back in.
In cities like San Francisco it was a tough slog to see more than two engineering firms in a day due to traffic and parking logistics. With online, virtual sessions you can present to their entire staff as well as any locations they have scattered around the world.
I’ve started limited travel myself for training events. I doubt cramming 30 or more folks into a hotel meeting room will ever be attractive anymore. In some cases moving the training into the shop area, parking lot or a large cafeteria area is a good option to allow attendees to spread out more.
I doubt anyone knows for sure how this will shake out or what “bug” will hit us next that makes people want to avoid crowded rooms and spaces, but plan on having options. Come up with new ways to engage the attendees. Not being able to see faces, expressions and not getting that in person feedback changes the game for a trainer. Add polls to your training to get some interaction and a feel for the groups. Consider multiple speakers or trainers to get some back and forth conversation in your online trainings.
The need for having a trained workforce is critical. Equipment is becoming more sophisticated and specific, so factory training will march forward. We would love to hear from all the players in the industry, thoughts suggestions, what we can do to keep you’ all coming back.
Let’s rid the ‘VID and get back to the normal face to face that we all crave.