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Design
The Fan Energy Index (FEI) helps you find high-performing fans that protect your intended design in the field. That’s why Greenheck’s eCAPS® online product selection program includes FEI. This simple but powerful metric leads the way to fans that have lower operating costs, quieter sound, and a more flexible operating range.
Enter a few project requirements and eCAPS will find and rank the fans that align best with your desired performance, features, and technology.
Compare FEI metrics sideby-side with sound levels, performance, first cost, and operating cost data.
Create schedules incorporating FEI, share code-compliant product cut sheets, and download AutoCAD® and Revit® drawings.
NEWS &BUSINESS
5 | These winners know how to navigate excellence
The 2026 40 Under 40 winners reveal the positive direction of the MEP industry.
BUILDING SOLUTIONS
7 | 40 Under 40
Read about the 2026 CSE 40 Under 40 winners.
22 | How to choose a water-cooled chiller and avoid pitfalls
Understand how water-cooled chillers are used to provide cooling as part of a chilled water hydronic system.
30 | How to conduct fire hydrant flow testing
Flow testing provides an overview of water supply and availability within a public distribution system.
How does a 40 Under 40 winner balance work, innovation, community and family?
Read on for more. See page 7.
ON THE COVER:
The 2026 40 Under 40 winners represent some of the top talent in the building community. Courtesy: Consulting-Specifying Engineer
36 | Know the risks involved in designing EV charging stations
Learn the risks associated with EV charging and the safety measures to address them.
ENGINEERING INSIGHTS
42 | Designing data centers for rapid growth and modularity
Engineers discuss how rapid growth in AI-driven workloads is reshaping data center design.
Check out exclusive technical ebook content at https://www.csemag.com/ebooks
SUNONDO ROY, PE, LEED AP, Director, Design Group, Romeoville, Ill.
JONATHAN SAJDAK, PE, Senior Associate/Fire Protection Engineer, Page, Houston
RANDY SCHRECENGOST, PE, CEM, Austin Operations Group Manager/Senior Mechanical Engineer, Stanley Consultants, Austin, Texas
MATT SHORT, PE, Project Manager/Mechanical Engineer, Smith Seckman Reid, Houston
RICHARD VEDVIK, PE, Senior Electrical Engineer and Acoustics Engineer, IMEG Corp., Rock Island, Ill.
TOBY WHITE, PE, LEED AP, Associate, Boston Fire & Life Safety Leader, Arup, Boston
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
These winners know how to navigate excellence
The 2026 40 Under 40 winners reveal the positive direction of the MEP industry.
Every year, I sit down with the finalized list of 40 Under 40 winners and am struck by the same sense of awe. This 2026 group, comprising consulting engineers and building industry specialists, represents more than just technical precision. These individuals embody a tireless drive to redefine the built environment. It is one thing to master the complexities of mechanical, electrical, plumbing (MEP) and fire protection systems, but another to wield that expertise as a tool for the industry’s progress.
Amara Rozgus, Editor-in-Chief
These professionals have been rigorously vetted and selected by a panel of their peers — judges who understand the high stakes of the industry and the exacting standards required to lead it. To be chosen in this field is no small feat, particularly as the challenges facing MEP engineers continue to mount. From navigating increasingly tight project timelines to stringent codes and standards to integrating evolving technology, the obstacles are significant. Yet these winners see friction as a catalyst for innovation rather than a deterrent.
Across every discipline, a clear set of priorities emerges: energy efficiency, sustainability and community resilience. These are not just buzzwords for this group, but the cornerstones of their practice.
Our winners are designing buildings that are safer, more resilient and more humane. Whether they are optimizing a hospital’s fire and life safety system to protect vulnerable patients or implementing microgrids, their motivation remains a blend of the technical and the altruistic. They are the essential translators between highlevel complexity and the basic human need for a stable built environment. What makes this group truly exceptional is that their drive does not stop when they leave the office. They are personally defined by curiosity. We see a recurring theme of mentorship, service and physical pursuits that require endurance and discipline. The same traits they bring to a challenging design — tenacity, self-renewal and a comfort with difficult problems — are the same qualities they cultivate in their downtime.
As I look at the 2026 winners, I see a generation of leaders whose identity is far broader than their technical skills. They are stewards of the systems that keep our buildings functioning and visionaries who understand that true value is measured by impact on the community. It is a privilege to celebrate their accomplishments. cse
Making tomorrow’s energy more resilient
Mining sits at the center of the global energy transition. As demand for critical minerals accelerates, operations must grow while reducing environmental impact.
Electrification, renewable integration, battery storage, and intelligent energy management are enabling mining operations to reduce emissions, improve efficiency, and strengthen system reliability.
To learn more, go to: Eaton.com/mining
Congratulations to all the 2026 Consulting-Specifying Engineer
40 Under 40 Honorees!
Each year, the Consulting-Specifying Engineer 40 Under 40 program shines a light on professionals who are not only ad vancing in their careers, but who are actively shaping the future of engineering. We are proud to congratulate the individuals named to this year’s 40 Under 40 list—leaders whose curiosity, courage, and commitment are redefining what’s possible.
Engineering today demands more than technical excellence alone. It calls for vision, resilience, and confidence to lead through complexity. As our industry navigates elec trification, digitalization, and an increasing focus on sustainability and resilience, your work stands out as proof that progress is driven by people willing to challenge con vention and move ideas into action. Your influence reaches far beyond individ ual projects. Through thoughtful design and
Chris M. Finen, P.E. National Application Engineer Manager Eaton
innovative thinking, you are helping create safer, more efficient, and more adaptable in frastructure that will serve communities for decades to come. With leaders like you, the future of engineering is not just capable—it is inspiring.
At Eaton, we are proud to support engi neers who are shaping this next chapter. As a leader in intelligent power management solutions, we remain committed to partner ing with you through technical expertise, forward‑looking technologies, and a shared purpose to improve the way the world is powered.
Congratulations again to the 2026 40 Under 40 honorees and thank you to Consulting-Specifying Engineer for recogniz ing these exceptional professionals. Togeth er, we are building a stronger, more resilient, and more sustainable future.
2026 Winners
Bryan Bucchianeri
10
Robby Deem 10
Khatera Dehzad 10
Jihan El Ouaragli 10
Joaquin Font 11
David Glenn
Alex Halloran
Sally Hassan
. . . . . 11
. . . . . 11
11
Marisa Higgins 12
Andrew Honeyman 12
Dhanraj Katkar 12
Mark Kelly 12
Chaitanya Korra 14
Ricky Limeburner
Richard Lopez
Lisa Lyons
. 14
14
. 14
Tyler Manahan 15
Dorian Maness 15
Spenser Meredith 15
Anthony Montez 15
Keiron D . Nanan
Ann Peratt
Melissa Poggi
. . . . . 16
16
16
Joanna Pyun 16
Eric Rushenberg 17
Bianca Schwanke 17
Jeff Seger 17
Harshal Shah
Sahil Shanghavi
Graham Smith
17
18
18
Greg Smithmyer 18
Tyler Stone 18
Alexandria Stuart 19
Nitish Suresh 19
James Taylor . . . . . . 19
Christine Tiffin . . . . . . 19
Christopher Unangst . . . . . . 20
Asrar Wasay 20
Stephen Wisniewski 20
Alec Zimmermann 20
Each winner is a multidimensional person who actively engages with the building profession, family and community.
BY FRANCES RICHARDS AND AMARA ROZGUS
Across disciplines, the 2026 40 Under 40 winners are consistently drawn to work that makes buildings safer, more resilient, more efficient and more humane. Their work is technical and the underlying motivation is both civic and human: protect occupants, improve operations, reduce waste, support communities and prepare institutions for the future. Beyond their careers, the commonality becomes even richer. Their personal interests suggest a cohort defined by curiosity and active engagement with the world. Family, mentorship and service appear frequently. Physical pursuits show up repeatedly. This physical drive points to shared traits: endurance, discipline, self-renewal and comfort with challenge. Taken together, these winner profiles portray a generation of leaders whose identity is broader than technical specialization. They are stewards of critical systems, translators between complexity and human need and multidimensional people whose passions reinforce the same qualities that make them effective professionally.
Bryan Bucchianeri, PE, 35
Regional Team Leader and Mechanical Engineer, CDM Smith; BS, Mechanical Engineering Technologies, Wentworth Institute of Technology
Bryan Bucchianeri has 13 years of experience specializing in the design and construction of complex heating, ventilation and air conditioning (HVAC) and plumbing systems for water and wastewater treatment facilities, industrial plants and public infrastructure projects. His technical expertise spans large-scale treatment process buildings, administration spaces and high-performance system retrofits, with a focus on energy efficiency, code compliance and long-term operational reliability. He has led the HVAC and plumbing designs for major facility upgrades incorporating advanced treatment technologies such as PFAS removal systems and nitrogen reduction processes — critical infrastructure improvements that help utilities meet evolving drinking water and environmental regulations. From early in his career, Bucchianeri demonstrated resilience and leadership. When his team was reduced significantly, he stepped into expanded responsibilities — serving as both a junior engineer and taking on mid-level and lead design duties. That challenge sharpened the skills that now define his approach. He currently manages a 23-person mechanical team across multiple Northeast offices, guiding technical excellence while mentoring younger engineers. Beyond project delivery, he contributes to the profession through published technical articles and participation in CDM Smith’s Technical Specialist Development Program. Bucchianeri treasures time with his wife and daughters, creating family traditions through travel, seasonal outings and beach days. He also enjoys cooking, grilling and, as a lifelong New England Patriots fan, gathering with friends to watch football.
Khatera Dehzad, PE, PMP, LEEP AP BD+C, 37
Senior Associate, BR+A Consulting Engineers; MS, Organizational Change Management, The New School
With nearly a decade of experience designing high-performance, sustainable building systems, Khatera Dehzad brings a thoughtful, multidisciplinary approach to engineering challenges that span complex infrastructure, academic, research and commercial projects. She began her career in fire protection, serving as the lead designer for fire protection systems at Newark Liberty International Airport Terminal 1. At BR+A, Dehzad expanded her expertise into mechanical engineering. She served as lead mechanical designer for the Princeton University Cancer and Imaging Center. Her work on the Watchtower Headquarters Project Ramapo supported the creation of an exceptionally sustainable, fossil-fuel-free campus, reflecting her commitment to decarbonization and forward-thinking design. A former Fulbright Scholar, Dehzad brings a global perspective that strengthens collaboration across diverse teams. Her leadership and technical contributions have been recognized with an Appreciation Award for Valuable Work from the U.S. Army Corps of Engineers. She has demonstrated a strong commitment to mentorship and advocacy, cofounding the Society of Afghan Women in Engineering and Construction to connect students from Kabul University with professional opportunities. Beyond her work life, Dehzad volunteers with a New York City nonprofit supporting blood cancer research and patient care. Fluent in four languages, she enjoys traveling and has visited more than 20 countries including Egypt, where she was especially inspired by the ancient architecture.
Robby Deem, LEED AP BD+C, WELL AP, 38
Principal, Vice President, TEECOM; MAE, Illinois Institute of Technology
Known for integrating technical expertise with a human-centered design approach, Robby Deem has built a career as an acoustical consultant, educ ator and team leader. His work spans architectural acoustics, environmental noise and vibration and multidisciplinary project management, where he emphasizes clear communication and measurable performance outcomes. Deem’s work life reflects a steady progression from technical specialist to trusted leader. Early in his career, he developed a “seller-doer” mindset that continues to shape his client relationships, grounded in responsiveness, long-term partnerships and consistent delivery. Deem manages multidisciplinary teams by fostering a culture of accountability, mentorship and professional growth. He is known for his ability to communicate complex ideas with clarity, while coaching team members to develop their own expertise. His commitment to sustainability is reflected in his credentials and design experience, including contributions to one of the first projects to achieve both LEED Platinum and WELL Platinum certification. Education and industry engagement are central to Deem’s professional identity. He served as an adjunct professor teaching acoustical modeling and remains active in organizations spanning acoustics, sustainability and the built environment. Beyond the office, Deem is an avid runner and has completed the Chicago Marathon 14 consecutive times. He also prioritizes outdoor exploration, working toward visiting all 63 U.S. national parks and enjoys skiing, photography and continuous learning, including studying Spanish.
Jihan El Ouaragli, 31
Staff Engineer, Jensen Hughes; PhD, Civil Engineering, Worcester Polytechnic Institute
Jihan El Ouaragli’s work sits at the intersection of sustainability, energy innovation and fire and life safety. She specializes in the safety of energy storage technologies, applying fire protection engineering principles to systems ranging from individual battery cells to electric vehicles and large-scale battery energy storage system (BESS) installations. As global demand for energy storage accelerates, El Ouaragli plays a key role in helping organizations deploy these technologies safely. At Jensen Hughes, she works in a rapidly evolving regulatory landscape where codes and standards are continually adapting to technological advancement. Her work has included leading fire safety design and code consulting efforts for major BESS manufacturers and developers, helping guide product design decisions through a rigorous safety lens. El Ouaragli has also led dozens of hazard mitigation analyses for energy storage installations across the United States on behalf of major utility companies. She serves as the technical lead for Jensen Hughes’ research program with supporting government-led initiatives, where she develops fire performance specifications for energy storage systems used in maritime environments. In addition, El Ouaragli provides industry education through training and presentations at major energy storage conferences including the NFPA Conference & Expo, where she co-led a workshop on BESS safety for more than 200 professionals. For relaxation, El Ouaragli enjoys learning languages and connecting with different cultures. She also loves cooking and experimenting with global cuisines, often drawing inspiration from European, Middle Eastern and North African culinary traditions.
Joaquin Font, PE, CEM, CEA, HBDP, LEED AP, 29
Senior Associate, BR+A Consulting Engineers; BS, Mechanical Engineering, Lafayette College
Working across sustainability as well as mechanical systems design, Joaquin Font is known for bridging technical engineering with energy strategy to deliver innovative, low-carbon solutions for complex facilities. Since joining BR+A, he has built a reputation as a trusted technical resource and collaborative leader. Font specializes in energy modeling, decarbonization strategies and code compliance, serving as a subject matter expert on New York City’s Local Laws and ASHRAE 90.1. His expertise supports major clients, including leading universities and global corporations, in navigating evolving energy regulations and achieving ambitious performance targets. Font has contributed to a wide range of technically demanding projects, including high-performance laboratories, health care facilities and large-scale campus developments. One example is the Watchtower Headquarters project in Ramapo, New York, a 2.1-million-square-foot, fully electrified campus featuring a geothermal-based central energy plant. Font brings deep expertise in advanced energy modeling tools and custom programming, often developing proprietary solutions to optimize complex building systems. Outside of work, Font is a dedicated endurance athlete, having completed major races including the Berlin and New York City marathons in 2023 and 2024. He is also an avid traveler who has visited more than 60 countries to enjoy skiing, surfing and hiking. At home, Font tackles hands-on home renovation projects that reflect his creativity and engineering mindset.
Alex Halloran, PE, 32
Healthcare Team Lead, HFA-AE; BS, Mechanical Engineering, University of Arkansas
Throughout his career, Alex Halloran has served as a client manager, project manager and engineer of record, building trusted relationships with clients while solving infrastructure challenges that directly affect patient care and safety. In his current role, he is a health care team lead with extensive experience delivering complex mechanical, controls, plumbing and heating, ventilation and air conditioning (HVAC) systems for health care and commercial facilities. Halloran is known for his hands-on approach and commitment to seeing projects beyond the stated scope of work. On a project at the University of Arkansas for Medical Sciences Radiation Oncology Center, he conducted multiple on-site investigations to address excessive HVAC noise and vibration that threatened the operation of a proton therapy machine. By developing and implementing targeted corrective actions, Halloran helped reduce vibration levels to within strict tolerances required for sensitive medical equipment. His leadership has also supported major health care infrastructure efforts, including overseeing 3D scanning work within active patient areas at Arkansas Children’s Hospital and leading efforts to reopen a previously condemned hospital in Jacksonville, Arkansas. During the COVID-19 pandemic, Halloran managed the rapid delivery of a 6,000-square-foot testing laboratory completed in just two weeks. In addition to project work, Halloran has trained engineering staff on advanced modeling tools and mentors engineers-in-training to help strengthen the next generation of professionals. He enjoys league bowling, hiking, deer hunting and traveling with his wife, activities that help him maintain balance while bringing focus and perspective to his engineering leadership.
David Glenn, RCDD, CTS-D, LEED AP BD+C, 37
Senior Principal, Director of Information and Communications Technology, SmithGroup; BS, Building Construction, Virginia Tech
Sporting a trifecta of accreditations, David Glenn is a technology infrastructure leader with extensive experience designing and managing complex information and communications technology systems for large facilities across the United States. He is recognized for his holistic approach to integrating telecommunications, building security, audiovisual and IT systems into the built environment. He has managed, designed and engineered technology infrastructure for more than 300 projects serving more than 150 clients nationwide. His work spans a wide range of sectors including higher education, health care, performing arts, government, aviation, transportation, research laboratories and commercial developments. Glenn’s expertise is distinctive because of his rare combination of credentials in telecommunications, audiovisual design, building security and sustainable building design. This perspective enables him to develop integrated technology strategies that support building performance, security and user experience. In addition, Glenn is known for his leadership and business development accomplishments. He has served as principal in charge for dozens of major assignments while also helping expand and lead multidisciplinary technology teams. Glenn is also active in professional organizations including BICSI, AVIXA and the Secure Building Council. To relax and recharge, Glenn enjoys spending time outdoors hiking, kayaking and fishing near the lake where he lives. He is also an avid Virginia Tech sports fan and enjoys photography and travel in his free time.
Sally Hassan, PE, PMP, 39
Senior Engineer, Arup; BS, Electrical Engineering, University of Technology – Iraq
With an interest in engineering that began as a child in Iraq, Sally Hassan’s career path reflects resilience, technical excellence and a commitment to improving the environments where people receive care. Growing up, an unreliable electrical infrastructure and frequent power outages were part of Hassan’s daily life. Seeing how the lack of dependable power affected homes, hospitals and communities inspired her to pursue engineering. Without family members or mentors in the profession, she became a first-generation engineer. Hassan began her career working for a contractor in Iraq, gaining valuable field experience that shaped her understanding of constructability, coordination and the realities of system installation. After relocating to Houston with her husband and young son, Hassan worked to establish herself in the U.S. engineering industry while adapting to new codes, standards and professional expectations. She has since built a strong reputation delivering electrical design for complex health care projects, including hospital replacement facilities, cancer center expansions, imaging suites and operating rooms. Known for her thoughtful design approach and strong client relationships, Hassan focuses on delivering electrical systems that prioritize safety, reliability and long-term performance. She is also involved in evaluating emerging energy solutions such as combined heat and power systems and microgrids. To relax, Hassan enjoys cooking, especially preparing traditional desserts such as kunafa and banana bread as well as spending time decorating her home and taking on small DIY projects. She also enjoys traveling, exploring new cuisines and spending time with her husband, children and extended family.
Marisa Higgins, PE, LEED GA, 31
Senior Mechanical Engineer, Arup; BS, Mechanical Engineering, The University of Texas at Austin
Marisa Higgins is known for delivering complex, high-impact projects across the health care and science, industry and technology markets. Her portfolio ranges from advanced clean rooms to major capital developments exceeding 1.6 million square feet, including prominent cancer care facilities and manufacturing environments globally. She oversees projects and helps lead multidisciplinary teams of up to 50 engineers while ensuring successful technical integration and client engagement deliver high-quality outcomes across ever-evolving designs. Higgins is widely recognized for her innovative, people-centered approach when it comes to engineering workflows and team efficiency. She has developed automation tools that significantly reduce manual effort and improve accuracy, including a process that transformed a 40-hour calculation workflow into a three-minute task. More recently, Higgins led the implementation of artificial intelligence-driven solutions that translate design data into formatted documentation. While her work reflects a consistent focus on scalability and usability for integrations, the defining hallmark of her character is her empowerment of others. She is deeply committed to fostering environments where team members are supported, heard and encouraged to grow. When she’s not at work, Higgins enjoys traveling internationally, exploring new cuisines and staying active through skiing, pickleball and outdoor adventures. She also values time spent discovering new restaurants and experiencing Houston’s vibrant food scene.
Dhanraj Katkar, 28
Application Engineer, Johnson Controls Inc.; BS, Mumbai University
As a diligent building automation engineer, Dhanraj Katkar is known for delivering building automation system (BAS) projects to fixed occupancy dates with clean and stable turnover. During his tenure at Johnson Controls that ended in 2025, he supported Metasys deployments across diverse commercial and industrial facilities, completing more than 100 control systems end-to-end. His work centers on the execution elements that determine field success: disciplined programming strategy, prefunctional readiness, commissioning coordination and rapid resolution of installation and integration issues before they create schedule risk. Katkar has served in both senior design engineer and application engineer roles, strengthening on-site execution by training more than 75 internal team members, subcontractors and client operators on tools, workflows and turnover best practices. On a large corporate headquarters project in Cleveland, he led onsite BAS execution through phased occupancy, overseeing heating, ventilation and air conditioning programming; functional testing; blackout readiness support; alarm monitoring and graphics verification while coordinating cross-functional teams. At an electric vehicle battery manufacturing facility in Kentucky, he led hardware submittals and direct digital control programming packages for approximately 430 controllers. A named inventor on a patent for intelligent load shedding in building controls, Katkar has earned both innovation and performance awards. Outside of work, he enjoys competitive go-kart racing, swimming and hiking to unplug, staying active and coming back sharper for work and study. Katkar is currently pursuing a master of science in engineering management at Trine University.
Andrew Honeyman, PE, 37
Business Development Manager/Mechanical Engineer, CMTA Inc.; BS, Mechanical Engineering, North Dakota State University
Andrew Honeyman is a consulting engineer and market leader who oversees CMTA’s industrial and central utility plant (CUP) market segments from the firm’s Fargo, North Dakota, office. A Fargo native himself, Honeyman began his career in Kansas City, where he contributed to the design of major nuclear and fossil fuel power plants. These experiences strengthened his technical expertise and laid the foundation for his later work in central energy plant and process engineering. After returning to Fargo, he expanded his work into complex industrial and energy infrastructure projects, including central energy plants, ethanol and biodiesel production facilities and agricultural processing plants. Since joining CMTA in 2017, Honeyman has played a key role in growing the firm’s presence in the industrial and CUP markets, helping the company exceed $1 billion in construction value for these projects. Honeyman’s expertise spans heating and cooling systems, cogeneration, geothermal technologies and other sustainable infrastructure solutions. His work includes projects ranging from lithium-ion battery manufacturing facilities to largescale university decarbonization initiatives, aviation central plant replacements and carbon-neutral geothermal systems. Beyond project delivery, Honeyman prioritizes building trusted relationships with clients and mentoring the next generation of engineers. He regularly speaks with students interested in STEM careers and shares insights on engineering education and professional development. Socially, Honeyman enjoys spending time with his wife and three young daughters traveling, exploring the outdoors, cooking healthy meals and staying active together.
Mark Kelly is known for his technical rigor, leadership and commitment to delivering high-performing building systems for complex facilities. Over the past decade, he has built a strong portfolio across health care, higher education and advanced research environments, where precise environmental control and energy performance are critical. He has developed a reputation for coordinating multidisciplinary teams and delivering mechanical solutions that balance innovation, sustainability and reliability. After gaining early experience with Leach Wallace Associates, Kelly moved to Boston in 2017 and joined BR+A. In this role, he manages intricate projects that require close coordination between architects, owners, contractors and engineering consultants to ensure systems meet performance goals while staying aligned with schedule and budget requirements. His portfolio includes major academic, health care and laboratory facilities such as Princeton University’s Quantum Institute for Quantum Science and Engineering, Boston Properties’ MXD Commercial Towers 250 & 290 Binney Street and multiple projects for Dana-Farber Cancer Institute and Boston University. Kelly also plays a key role in mentoring junior engineers and strengthening firm culture by creating opportunities for professional development. To remain balanced, Kelly enjoys outdoor adventures and travel with family and friends. An avid skier since childhood, he regularly makes weekend trips from Boston to Vermont and travels to the Rocky Mountains each year for high-altitude slopes. The couple also seeks out challenging hikes at national parks and travel to international destinations, combining their love of travel with a passion for exploring new landscapes and cultures.
Making digging to low-carbon work
Rising global demand is placing new emphasis on how minerals are produced, while sustainability expectations are reshaping how mining sites are designed, expanded, and evaluated. Legislation, investor priorities, and community expectations are accelerating the shift toward greater energy efficiency, lower emissions intensity, and increased digitalization across mining operations.
Senior Design Manager, Redwood Materials; Master of Architecture, University of New Mexico
Chaitanya Korra is a sustainability-driven design leader with more than a decade of experience delivering mission critical and industrial infrastructure across architecture, engineering and clean-energy manufacturing environments. He manages full project life cycles from strategy and schematic design through commissioning and turnover, translating complex goals into structured execution plans that align cost, schedule, resiliency and energy-performance targets. Formally trained as an architect, Korra combines building-science fundamentals with rigorous documentation practices and standards-based coordination. His credentials support his work integrating sustainability, decarbonization and reliability objectives into high-hazard and high-performance facilities. At Redwood Materials, Korra leads infrastructure design for advanced lithium-ion battery recycling and refining facilities that support the U.S. circular-economy supply chain. He coordinates architecture, engineering, construction and process teams to mitigate design risk, navigate regulatory constraints and embed long-term operational efficiency into project strategy. Korra advocates for practical innovation, applying building information modeling, digital twins and building management systems. He also mentors emerging professionals and contributes to industry organizations. A multilingual professional known for clear communication and calm leadership, Korra builds collaborative teams that deliver complex projects while advancing sustainable infrastructure. His interests include kayaking, badminton, cricket, hiking, camping, photography and literature.
Richard Lopez, PE, 38
Mechanical Engineer, CMTA Inc.; BS, Mechanical Engineering, Washington University in St. Louis
With more than a decade of experience, Richard Lopez delivers innovative mechanical solutions across K-12 education, community facilities and commercial buildings, helping clients achieve sustainable, resilient and cost-effective designs. His work focuses on designing high-performance building systems that improve energy efficiency, reduce operating costs and create healthier environments. Based in CMTA’s Houston office, Lopez leads mechanical design efforts and collaborates closely with architects, contractors and building owners. His expertise includes central plant design, geothermal well fields, hydronic systems, radiant floor heating, energy recovery units and variable-speed air handling systems. He has contributed to numerous LEED-certified and net-zero energy projects that prioritize long-term building performance and occupant well-being. Lopez is known for translating engineering challenges into practical, buildable solutions that align with project budgets and sustainability goals. He helps stakeholders understand how design strategies can improve building performance without increasing first costs. His work on large school campuses in Texas demonstrates how high-efficiency mechanical systems can significantly reduce long-term operational expenses. In addition, Lopez is committed to mentoring as he works with emerging professionals to build technical expertise while encouraging a problem-solving mindset. To recharge, Lopez enjoys spending time with his wife and two children. He also enjoys playing tabletop games with friends, working out while listening to podcasts or audiobooks and canoeing with his family whenever he has the chance.
Ricky Limeburner, CEM, CxA+BE, BEAP, 37
Senior Energy Engineer, Cyclone Energy Group; BS, Mechanical Engineering, Florida Institute of Technology
Ricky Limeburner’s work focuses on building automation, retro-commissioning (RCx), monitoring-based commissioning and energy engineering for large commercial, institutional and health care facilities. With more than 10 years of experience optimizing building systems, he has a reputation for delivering measurable energy and cost savings through data-driven analysis, optimized control strategies and collaborative engagement with clients and teams. At Cyclone Energy Group, Limeburner manages energy engineering projects and consulting efforts for commercial and institutional clients, aligning building performance with financial and sustainability goals through analysis and practical implementation strategies. His work includes identifying and implementing energy conservation measures, optimizing building automation system sequences and providing technical guidance on control strategies, sensor selection and system integration. His professional impact is demonstrated through project results that have delivered more than $800,000 per year in verified energy cost savings across multiple projects. One notable achievement was an RCx effort for a 640,000-square-foot office building in Chicago that achieved verified savings of more than 750,000 kWh annually. In addition to his day job, Limeburner is active in community service with the Brooksville (Maine) Historical Society, the Brooksville Farmers Market Committee and local service initiatives supporting food banks and community organizations. He also enjoys hunting, fishing, motorcycle rides and spending time with his wife and son.
Lisa Lyons, PE, LC, Assoc. IALD, 40
Lighting Business Class Lead, HDR Inc.; MS, University of Nebraska at Lincoln
Lisa Lyons is a lighting designer and electrical engineer whose expertise in architectural lighting design has shaped projects across health care, civic, commercial, federal, hospitality and higher education environments. Her work focuses on integrating lighting within architecture to provide a visual hierarchy of exterior and interior elements that evoke emotion while conveying purpose within a space. Lyons believes that both natural and artificial light have a profound impact on shaping the human experience while promoting environmental sustainability, enhancing controllability and streamlining maintenance. Within HDR’s lighting design team, Lyons advanced from lighting designer to lighting design section manager and later to lighting business class lead, guiding a team of 11 staff members across multiple offices. Her leadership approach is grounded in a comprehensive understanding of her team’s professional skills and personal traits. Lyons has delivered award-winning work on a variety of high-profile projects. Beyond project work, Lyons has maintained a longstanding commitment to education and mentorship at the University of Nebraska-Lincoln’s architectural and engineering program, participating in the team design course and mentoring students since 2010 and now serves on the Durham School Architectural Engineering Industry Advisory Committee. Away from the office, she enjoys traveling and spending time with her family. She and her husband stay busy with their two daughters, supporting their sports and activities and enjoying craft projects together throughout the year.
Tyler Manahan, PE, 39
Project Manager, Alvine; BS, Electrical Engineering, University of Central Oklahoma
Tyler Manahan brings nearly two decades of experience as an electrical engineer, delivering energy-efficient, cost-effective electrical and lighting designs. Currently serving as a project manager and resource manager at Alvine, he has demonstrated strong technical leadership while supervising more than 50 projects and mentoring to strengthen the professional development of junior engineers. His approach combines technical precision with clear communication, enabling him to guide clients and teams through complex design challenges while keeping project goals and end-user needs at the forefront. Manahan’s diverse project portfolio spans government, health care, higher education, commercial and large-scale mixed-use developments. He played a key role in completing the electrical design for the Waterline tower in Austin — the tallest building in Texas — stepping into the project mid-design and leading final coordination and construction administration. His portfolio also includes the Jim Thorpe Memorial Building renovation in Oklahoma City, electrical and lighting design for the Girl Scouts Camp Trivera Lodge and coordination of power system configurations for a Boeing lab. Beyond project work, Manahan contributes to the advancement of the profession as president of the Illuminating Engineering Society’s Oklahoma City chapter and through mentoring and judging student lighting design competitions. Manahan is deeply engaged in community service and family life. He volunteers with organizations such as the Oklahoma Humane Society and Myriad Gardens’ Pumpkinville event, supports ministry outreach through his church and spends much of his personal time cheering on his daughter’s competitive softball team.
Spenser Meredith, PE, 31
Lead Professional, Mechanical Engineer, WSP; BS, Mechanical Engineering, Texas A&M University
Spenser Meredith is a health care-focused mechanical engineer with a decade of experience delivering highly technical mechanical and plumbing solutions for complex hospital environments. His expertise lies in navigating the intersection of building codes, clinical requirements and constructability — particularly in how hospital spaces affect medical staff and patients. Known for his methodical approach, Meredith excels in above-ceiling coordination, air handling system improvements and infrastructure upgrades that demand precision within tight existing conditions. A trusted client-facing engineer for major health care systems, he has contributed to numerous renovations, equipment replacements and tower expansions across Texas and beyond. His technical strength is particularly evident in imaging equipment replacements. Meredith approaches these challenges with a calm, analytical mindset. Beyond design, he plays an active role in construction administration and quality control, ensuring systems are installed as intended and perform reliably in real-world clinical settings. Colleagues value his faithful and steady leadership and his commitment to mentoring junior engineers, walking them through redlines, models and submittals so they understand not just what decisions were made, but why. He is actively involved with CANstruction, Habitat for Humanity and local STEM events. Outside of work, Meredith enjoys hiking, golfing and experimenting with grilling and smoking techniques. He is also a youth mentor and leads seventh-grade Bible study. Whether on a trail or at a backyard smoker, he brings the same steady, thoughtful presence that defines his professional success.
Dorian Maness, GGP, 33
Senior Mechanical Engineer, Project Manager, Matern Professional Engineering; BS, Mechanical Engineering, University of Central Florida
Known for intricate design solutions, Dorian Maness oversees complex heating, ventilation and air conditioning (HVAC) and central energy plant designs while guiding multidisciplinary teams through every stage of project delivery. He has built his career around creating efficient, sustainable building systems. Maness is experienced in designing advanced HVAC systems that incorporate both air- and waterside strategies, including cooling towers, thermal energy storage and central energy plants. His work often focuses on optimizing energy performance while meeting the operational needs of large campuses and public institutions. In his leadership role, Maness manages project teams, coordinates consultants and maintains quality control across projects including K-12 schools, higher education, municipal and commercial facilities. He is known for translating complex mechanical and energy concepts into clear direction for clients, contractors and design partners, ensuring projects remain aligned with performance goals and budgets. His project experience includes large-scale campus infrastructure such as the 600,000-square-foot expansion of The Villages Charter School in Middleton, Florida, which features one of his largest central energy plant designs to date. Beyond project work, Maness mentors younger staff and has helped transform Matern’s internship program into a strategic pipeline for new talent. To unwind, Maness enjoys spending time on the water boating and fishing, traveling to explore different cultures and architecture and discovering new restaurants in the Orlando area with his wife. He is passionate about supporting local restaurants and businesses.
Anthony Montez, PE, CxA, 34
National Commissioning Leader, DLR Group; BS, Mechanical Engineering, University of Illinois Urbana-Champaign
With a full life cycle perspective that spans planning and design through construction and operations, Anthony Montez ensures building systems are installed, tested and performing exactly as intended. By reviewing design documents, contractor submittals and directing functional testing, he bridges the gap between design intent and operational performance. With more than a decade of experience in the design-build industry, Montez provides technical leadership and strategic direction. Since joining DLR Group, he has demonstrated sustained career growth, culminating in his role leading commissioning efforts nationwide. He provides technical oversight across a diverse portfolio of projects and market sectors, continuously refining commissioning methodologies to enhance coordination, improve efficiency and elevate building performance. Known for his integrity, reliability and consistency, Montez has built a reputation as a trusted advisor who aligns multidisciplinary teams around shared goals and delivers outcomes that perform as promised. His project experience spans major education, civic and commercial facilities nationwide. Beyond project execution, he actively contributes to advancing best practices in commissioning through participation in industry organizations and conference presentations. While not working, Montez enjoys playing soccer, taking on home improvement projects or living his best life as a new father. He is also an active volunteer for Big Brothers Big Sisters Minneapolis. Whether on the field playing soccer or at home, he brings the same discipline, teamwork and commitment to excellence that define his professional success.
Consulting-Specifying
Keiron D. Nanan, SFP, 34
Director, Temp Tec Limited; MS, Energy Efficiency and Renewable Energies, Universidad Alfonso X el Sabio
Astrategic thinker with deep technical expertise, Keiron D. Nanan has built a career dedicated to advancing sustainable infrastructure and energy efficiency across the Caribbean. He works at the intersection of engineering, policy and project development, helping governments and organizations implement resilient, energy-efficient systems that support long-term economic and environmental goals. One of Nanan’s recent roles involves serving as a technical lead on a World Bank Group–funded initiative supporting the update of the CARICOM Energy Efficiency Building Code. Through this effort, he advises governments in Grenada, Guyana and St. Lucia on aligning national building codes with international standards, helping create investment-ready infrastructure frameworks while improving building performance and resilience. Earlier in his career, Nanan demonstrated strong business leadership as director and sales manager at Temp Tec Limited, where he expanded operations into new Caribbean markets and implemented strategies that increased revenue and improved operational efficiency. Alongside his consulting and business work, he has played a leadership role with ASHRAE. Nanan remains involved in community initiatives and youth mentorship. He serves as a trustee and advisor for local organizations that promote sports, recreation and community development, often mentoring young professionals and helping organize activities that encourage teamwork and leadership. In his personal time, he enjoys cricket, football, golf and squash, along with cooking, traveling and spending time with family and friends.
Melissa Poggi, PE, CEM, LEED AP, 38
Consulting Application Engineer, Schneider Electric; BS, Electrical Engineering, University of Delaware
Known as a lifelong learner, Melissa Poggi has over 17 years of experience, dedicated to electrical design, construction and infrastructure development across a wide range of industries. Her work spans the full life cycle of engineering projects, including conceptual planning, design, analysis, testing and field commissioning for sophisticated electrical systems such as data centers, cogeneration facilities, solar and wind installations, substations and multibuilding distribution networks. Poggi’s technical expertise includes preparing construction drawings and specifications for low- and medium-voltage power systems, building electrical system models and performing condition assessments and life cycle analysis. In her current role, she works with consulting engineers on layouts, specifications and pricing while reviewing her clients’ bill of materials orders. She is known as an expert in microgrid design. Throughout her career, Poggi has been recognized for her ability to simplify electrical challenges and communicate solutions to clients and project teams. She remains active in the engineering community through leadership roles with the IEEE Power & Energy Society and participation in the Society of Women Engineers. Poggi is passionate about obstacle course racing and functional fitness competitions, having completed more than 200 races internationally. She also serves on the Lone Star Spartan leadership council where she helps inspire athletes from diverse backgrounds to pursue healthy lifestyles and push beyond perceived limits. She enjoys hiking local trails, exploring scenic outdoor locations and snowboarding whenever she can.
Ann Peratt, PE, 39
Principal, PKMR Engineers; MS, Architectural Engineering, Kansas State University
Ann Peratt blends technical excellence with a people-first leadership philosophy at PKMR Engineers. Since joining the firm in 2012 as a staff mechanical engineer, she has grown alongside the company — becoming an associate principal on the leadership team in 2019 and later stepping into an ownership and a principal role. She now helps shape PKMR’s strategic vision, oversees human resources and marketing and plays an active role in business development and company growth. Throughout her career, Peratt has led a diverse portfolio of projects spanning health care, higher education, public safety, hospitality, office, religious and senior living facilities. She has managed and mentored multidisciplinary teams on complex projects such as fire stations, surgery centers, university facilities and large-scale hospitality venues. Known for her strong technical foundation in heating, ventilation, air conditioning and plumbing design, she is equally respected for building trusted client relationships and mentoring emerging engineers. Peratt is deeply committed to advancing the engineering profession. A longtime member of ASHRAE, she served as president of the Kansas City Chapter in 2021-2022 and earned the ASHRAE Chapter Service Award in 2022. She has also supported the Society of Women Engineers and participated in outreach initiatives introducing young students to engineering. In her free time, Peratt enjoys traveling with her husband and two daughters and playing on her firm’s sand volleyball team. She is also involved in her local church, where she coached youth volleyball. Whether leading teams, serving her community or raising a family, she approaches each role with empathy, purpose and a dedication to building meaningful relationships.
Joanna Pyun, PE, 37
Principal, Affiliated Engineers Inc.; BS, Mechanical Engineering, Boston University
Joanna Pyun leads complex infrastructure and energy projects supporting major institutions’ transition toward more sustainable, resilient utility systems. Known for her collaborative leadership style and practical engineering mindset, Pyun has built a career focused on solving technical challenges while strengthening relationships across project teams. Her experience spans district energy systems, campus utility infrastructure and large-scale decarbonization initiatives for research, health care and higher education facilities. Rather than entering consulting immediately after college, she first worked for a general contractor, gaining hands-on experience with infrastructure projects such as constructing wind turbines, boiler plants and movable bridge systems. This early field experience gave her a deeper understanding of constructability, budgeting and project coordination — skills that continue to shape her approach today. Since joining Affiliated Engineers Inc. (AEI) in 2017, Pyun has played a key role in some of the firm’s most impactful energy transition projects. In addition to her project work, she leads AEI’s San Francisco mechanical department, overseeing a team of engineers while serving as a mentor for emerging professionals. Pyun also volunteers with organizations addressing food insecurity and homelessness, participates in Habitat for Humanity projects and helps organize volunteer efforts that bring her colleagues together for community service. In her free time, she enjoys hiking and camping throughout the Bay Area, playing piano and staying informed on global events through reading the daily news and listening to podcasts.
Eric Rushenberg, PE, 37
Technology, Media and Telecommunications Sector Leader for Nebraska and Iowa, HDR Inc.; MS, Architectural Engineering, University of Nebraska–Lincoln
Known for aligning technical execution with business objectives, Eric Rushenberg serves as a strategic partner to hyperscale data center clients nationwide. In his current role, he leads complex, multidisciplinary teams through every phase of delivery — from early stakeholder engagement and concept development to construction administration and final turnover. His leadership blends rigorous electrical engineering expertise with strong interpersonal skills, building trusted client relationships while driving schedule certainty and design excellence. Since joining HDR in 2018 as a lighting designer, Rushenberg has advanced through project management into market sector leadership, sustaining a trajectory defined by innovation and measurable impact. He pioneered a photometric simulation methodology to analyze camera views and coverage strategies, enhancing coordination and performance outcomes. A strong advocate for automation, he regularly implements macros and scripting tools to streamline workflows, improve efficiency and elevate project delivery standards. His work has earned Illuminating Engineering Society awards for interior and exterior lighting, as well as ACEC recognition for Liberty Middle School. An Eagle Scout himself, he serves as Cubmaster for his son’s Cub Scout pack, rarely misses his children’s games or dance recitals and volunteers with Together Omaha and United Way. Rushenberg’s progression from engineer-in-training to market leader reflects sustained technical excellence and a steadfast commitment to community, family and professional growth.
Jeff Seger, PE, LEED AP BD+C, 39
Mechanical Engineering Discipline Leader, CannonDesign; BS, Architectural Engineering, University of Kansas
Soon after joining CannonDesign’s Chicago office in 2021, Jeff Seger led a team of 10 mechanical engineers to complete construction documentation for a 140,000-square-foot educational building at the University of Illinois at Urbana-Champaign pursuing LEED Platinum certification. He now co-leads construction administration for that project while continuing to support other campus initiatives. Recently named mechanical discipline leader for the Chicago office, he helps guide staffing strategy, provides technical mentorship to engineers and works with project managers to ensure teams are positioned for success. He is also co-leading a firmwide initiative to strengthen internal continuing education programs for mechanical engineers. Seger began his career in Kansas City as a commissioning agent and LEED certification facilitator. Recognizing his potential as a design engineer, his supervisor introduced him to health care engineering, setting the direction for much of his career. Seger has contributed to several complex health care projects while at various firms. More recently, he has supported CannonDesign’s ongoing work with Mayo Clinic in Rochester, Minnesota, and the Heartland Whole Health Institute in Bentonville, Arkansas. Outside of project work, Seger regularly shares design insights through internal presentations and industry forums. He enjoys staying active through hiking, weightlifting, CrossFit and Hyrox — and balances those pursuits with his passion for cooking. His love for Legos completes the picture.
Bianca Schwanke, PE, 39
Fort Worth Office Leader, CMTA Inc.; BS, Mechanical Engineering, The University of Texas at Arlington
Bianca Schwanke has more than 15 years of experience designing and managing mechanical and plumbing systems for complex health care and commercial facilities. She leads project teams through the planning, design and coordination of high-performance building systems, with a particular focus on hospitals, medical office buildings and ambulatory surgery centers. In her role as a project manager and department leader, Schwanke oversees the mechanical and plumbing design process from concept through construction. She manages the production and review of project drawings, coordinates multidisciplinary teams and mentors designers while ensuring projects meet technical standards, budgets and deadlines. Schwanke’s health care portfolio includes major renovations, equipment upgrades and facility expansions. Her experience also includes highly specialized environments such as radiation oncology facilities, behavioral health centers and catheterization laboratories. One of the most notable projects of her career is the Panhandle State Hospital in Amarillo, Texas, a complex behavioral health facility that required careful planning and collaboration across multiple engineering disciplines. Projects like these have helped establish Schwanke as a trusted technical leader known for managing demanding work while maintaining strong client relationships. She is active in several industry organizations, including ASHRAE and the ASHE. To balance her work life, Schwanke enjoys spending time with her husband and two daughters as well as creating art with watercolor and colored pencil. The family shares a love of travel and outdoor adventures, including hiking, camping and annual snowboarding trips.
Harshal Shah, PE, LEED AP BD+C, CEM, HFDP, 34
Senior Project Manager, A&J Consulting Engineering Services PC; MS, Mechanical Engineering, University of Bridgeport
An opponent of the cookie-cutter approach, Harshal Shah is known for designing plumbing, fire protection and heating, ventilation and air conditioning (HVAC) systems for commercial, institutional and office buildings. He also manages a multidisciplinary engineering team and coordinates closely with clients, architects and other trades. His work focuses on managing and scheduling mechanical, electrical and plumbing projects; reviewing design and calculations; supporting construction administration; and developing standards that maintain the quality of design while implementing applicable building construction codes into project designs. Shah performs ventilation and heating load calculations, designs toilet exhaust systems and monitors construction by reviewing shop drawings and periodically inspecting work performed by contractors on site. He has also designed HVAC, plumbing and fire protection systems for large facilities, including fully electric public schools and recreation centers. His project work includes designing complex fire protection systems such as combined standpipe-sprinkler systems, dry pipe systems and chemical-based clean agent suppression systems for specialized facilities. Outside of work, Shah enjoys hiking, camping and snowshoeing and often explores the outdoors accompanied by his trained Maine Coon cat. He is also a passionate home chef, photographer and woodworker who enjoys designing and building custom furniture with his wife to benefit their newborn daughter.
Consulting-Specifying Engineer 40
Sahil Shanghavi, 38
Director of Sales, ASCO Power Technologies –Schneider Electric; MS, Electrical Engineering –Energy Systems, The University of Texas at Austin
Passion for the power industry started as a child during nighttime power outages, propelling Sahil Shanghavi’s career toward becoming a commercial leader in the power and energy sector. He now blends deep engineering expertise with strategic business leadership. Over the course of his career, he has shaped high-performing teams, strengthened customer relationships and accelerated growth across mission critical, health care, industrial and data center markets. His foundation in complex power systems has enabled him to influence designs at the early stage and guide large, multidisciplinary teams. His ability to simplify intricate electrical system challenges and translate them into strategic decisions has made him a trusted advisor to customers navigating digital substation innovation and modern grid protection strategies. He has also demonstrated a commitment to mentorship, guiding more than 75 individuals throughout his career and reinforcing his belief that leadership is measured by uplifting others. He supports underprivileged children in his hometown of Kolkata, India, and organizes grassroots food drives during visits. Through Schneider Electric, he participates in Habitat for Humanity builds and STEM outreach initiatives. Outside of work, Shanghavi stays energized through beach volleyball, as a private pilot, morning gym sessions and global travel with his wife and newborn daughter, whom they recently welcomed and are excited to include as part of their travel entourage. Having visited 35 countries and nearly all 50 U.S. states, he embraces life as a multilingual global citizen — bringing curiosity, resilience and perspective to both his professional and personal pursuits.
Greg Smithmyer, PE, LEED AP BD+C, 40
Senior Project Engineer, Affiliated Engineers Inc.; MAE, The Pennsylvania State University
Greg Smithmyer is a mechanical engineering leader whose career reflects technical excellence, collaborative leadership and a dedication to service. Since joining Affiliated Engineers Inc. (AEI) in 2009, he has built a reputation for delivering complex solutions across science and technology, health care and higher education facilities. Known for his steady leadership and collaborative mindset, Smithmyer has earned the trust of clients, architects and contractors by guiding multidisciplinary teams through technically demanding projects while maintaining clear communication. His project experience includes major health care and research facilities across the U.S. Smithmyer has also played key roles in facilities that employed integrated project delivery methods, requiring collaboration among designers, contractors and owners. Within his firm, Smithmyer is recognized as both a technical resource and a mentor. He leads the mechanical engineering group in Chapel Hill, North Carolina, supporting engineers across multiple offices while advancing firmwide initiatives to improve quality, training and engineering standards. Outside of work, Smithmyer dedicates time to community service and family activities. He volunteers with Habitat for Humanity, supports food security efforts through the Dorcas Food Pantry and Feed the Hunger and serves meals at organizations assisting individuals experiencing homelessness. He also enjoys spending time with his family through outdoor adventures, attending theater performances at the Durham Performing Arts Center and trying new wines with his wife.
Graham Smith, PE, CEM, CDP, 38
Mechanical Engineer, CMTA Inc.; BS, Mechanical Engineering, Arizona State University
With more than 14 years in the design, analysis and optimization of building systems, Graham Smith places a strong emphasis on energy efficiency, decarbonization and high-performance facilities. His career reflects a hands-on understanding of the entire building life cycle, from advanced engineering design to construction and system installation finishing with commissioning skills. Smith began his career in the heating, ventilation and air conditioning industry as a controls technician, where he developed an understanding of building systems and identified opportunities to improve operational efficiency. This early experience laid the groundwork for his collaborative and solutions-focused approach. He later joined Honeywell, where he installed controls systems for luxury hotels across North America. Smith then transitioned into energy engineering and commissioning services with CLEAResult. In this role, he performed energy modeling and on-site commissioning while supporting communities. He later joined CMTA as a commissioning and design engineer, where he has worked extensively on complex health care facilities. For example, at Massachusetts General Hospital, he retro-commissioned 13 buildings, helping remove more than 8.5 million kWh of electricity and 22 million pounds of steam usage. To recharge, Smith enjoys hiking in the mountains of the Northeast with his wife and two children. During winter, he spends time skiing, playing hockey and coaching youth sports. He also enjoys traveling to major cities and remote landscapes around the world.
Tyler Stone, LC, CLEP, CLMC, 36
Lighting Team Leader, CMTA Inc.; BA, Business and Organizational Communication, University of Kentucky
Tyler Stone is a seasoned lighting design and energy solutions professional with more than 12 years of experience spanning product management, project leadership and technical design. As a principal and lighting team lead at CMTA Energy Solutions, he oversees multidisciplinary teams of lighting specialists and electrical engineers, guiding projects from initial site assessment through design, procurement and construction. Known for his ability to align technical precision with client goals, Stone consistently delivers high-performance, energy-efficient solutions that enhance both functionality and user experience. With an unconventional approach, Stone brings a distinct business advantage to the engineering space. He excels at translating complex technical concepts into clear, actionable strategies, fostering strong relationships with clients and collaborators alike. Early in his career, he built a reputation as a trusted resource, conducting large-scale lighting assessments and managing turnkey solutions across higher education, industrial and commercial facilities. Stone’s leadership is defined by a balance of analytical rigor and creative problem-solving. His work reflects a deep understanding of energy codes, emerging technologies and the human impact of lighting. To relax, he enjoys hiking challenging trails, playing golf on notable courses and traveling with his three children, where they share a meaningful tradition of watching sunrises and sunsets together. He’s also deeply involved in providing services in underserved communities.
Alexandria Stuart, PE, 30
Mechanical Engineer, CDM Smith; BS, Mechanical Engineering, University of Florida
Alexandria Stuart has nearly a decade of experience specializing in plumbing systems and heating, ventilation and air conditioning (HVAC) for complex infrastructure and utility projects. She has developed a reputation for technical expertise, thoughtful leadership and a commitment to high-quality solutions. After expanding her knowledge at other firms, Stuart returned to CDM Smith, where she contributes to design efforts and builds relationships with colleagues and clients. Stuart’s project portfolio includes water and wastewater treatment facilities, pump stations and federal infrastructure projects. She has led or contributed to mechanical HVAC and plumbing design for projects including water treatment plants, a water purification facility and multiple utility improvements at an air base. Known for her ability to translate complex concepts into practical design solutions, she consistently delivers work that balances innovation, reliability and operational efficiency. She is recognized for her mentorship and commitment to professional development. She was selected for CDM Smith’s Technical Specialist Development Program, which prepares emerging leaders within the firm. Stuart remains active in both community service and personal pursuits. She volunteers with Special Olympics soccer and organizes a monthly effort with her boyfriend to prepare and distribute homemade breakfast sandwiches to unhoused individuals. In her free time, Stuart stays active through soccer, running, rollerblading, pickleball and spending time with her two Pomeranians, Gus and Ink. She enjoys puzzles, card games with friends and family and other activities that challenge her mind while helping her recharge outside of work.
James Taylor, PE, 38
Principal and CEO, ACS Group; MBA, University of Nevada, Las Vegas
James Taylor provides leadership on complex, high-accountability fire protection engineering and life safety consulting across diverse and evolving building environments. His career reflects a consistent focus on sound technical judgment, responsible leadership and long-term stewardship within the fire protection industry. He brings a multidisciplinary perspective to his work, grounded in advanced technical education and formal business training. Rather than relying solely on prescriptive approaches, he evaluates risk holistically, considering system performance, operational realities and regulatory intent. This approach has made him a trusted advisor on projects where emerging technologies, nontraditional occupancies or novel hazards require careful interpretation and clear communication among stakeholders. Taylor is frequently engaged on projects involving performance-based design, alternative compliance pathways or heightened coordination with regulatory authorities. In these complex environments, he emphasizes clarity, documentation and collaboration, helping project teams develop solutions that prioritize life safety while remaining practical to construct, operate and maintain. Taylor is known for his direct communication style and his ability to translate technical considerations into clear guidance for owners, designers and operators. As a firm leader, he remains actively involved in technical oversight while guiding strategic planning and operational decision-making. Outside of work, Taylor enjoys skiing, traveling and trail running. He has participated in endurance events including the Red Rocks Ultra Marathon and Mammoth Trail Fest and regularly hikes with fellow entrepreneurs through Founders Hikes in Southern Nevada.
Nitish Suresh, PE, 32
Energy and Commissioning Specialist, Zodiac Inc.; MS, Mechanical Engineering, Syracuse University
Acommissioning, modeling and energy specialist, Nitish Suresh’s career has rapidly advanced from entry-level engineer to a leader on some of the region’s most complex health care and government projects. With expertise spanning building commissioning, energy modeling and sustainability documentation, he approaches each project with a holistic understanding of how mechanical, electrical, plumbing and envelope systems must function together over decades of operation. Suresh played a central role in the Washington University Campus Renewal Project, commissioning and energy modeling a 17-story, 660,000-square-foot health care tower in St. Louis. His work included an energy analysis and benchmarking — including steam heating, water-cooled centrifugal chillers, heat recovery chiller, cooling towers, air handling units and other heating, ventilation and air conditioning equipment. By developing tailored commissioning plans and LEED-specific workflows, he has helped streamline certification processes and elevate performance standards. An active leader within ASHRAE, Suresh serves as historian for the St. Louis Chapter and contributes to advancing industry best practices through professional service and conference presentations. Colleagues and clients alike value his integrity and his belief that commissioning is not a checklist exercise, but a promise of quality to building occupants. Outside of work, Suresh recharges by hiking Missouri trails and national parks, riding his motorcycle and spending time bowling or catching a movie with friends — bringing renewed energy and perspective back to every project he leads.
Christine Tiffin, AIA, LEED AP BD+C, ID+C, WELL AP, 37
Senior Consultant, Sustainable Materials, Arup; MDes, Energy & Environments, Harvard University
Christine Tiffin is a senior consultant on Arup’s Sustainability, Climate, Resilience and Environment team whose career has centered on advancing embodied carbon strategies, whole-building life cycle assessment and healthy materials across the built environment. She helps teams make more informed design decisions using data and computational tools that integrate easily into real workflows. Tiffin frequently supports major projects by providing robust analytical support that enables teams to make positive selections for their projects that consider climate impact and human health. She has contributed to a wide range of commercial, mixed-use, residential and urban design projects and often consults on global projects given her expertise in embodied carbon of building services equipment and systems. In her role, she leads teams conducting whole-building life cycle assessments across multiple projects to identify decarbonization opportunities and develop reduction roadmaps for implementation. Tiffin also has supported major infrastructure and civic projects. At San Francisco International Airport, she led sustainability, healthy-buildings and circularity initiatives and she managed certification efforts that resulted in LEED BD+C Platinum for Harvey Milk Terminal 1 Boarding Area B, while also supporting the achievement of WELL Building Standard Platinum. Beyond project delivery, she leads Arup’s Embodied Carbon Working Group. Outside of work, Tiffin enjoys hiking the Bay Area’s coastline, redwood forests and mountainous landscapes, as well as woodworking and spending time with her rescue dog, Caba.
Christopher Unangst, PE, CSP, PMP, 39
Director, Jensen Hughes; BS, Chemical Engineering, University at Buffalo
Adirector with Jensen Hughes’ Industrial and Process safety group, Christopher Unangst leads a team of more than 15 engineers supporting clients across the U.S. With nearly two decades of experience in safety engineering, he specializes in combustible dust hazard analyses, process hazard analyses, hazardous materials safety and industrial hygiene. Known for his servant leadership style, Unangst prioritizes developing the engineers he supervises while delivering technical, sound, practical solutions that help clients manage risk and maintain safe operations. Unangst has built a reputation as a trusted advisor to organizations navigating complex safety and regulatory requirements. His work includes conducting facility safety assessments, leading process hazard analyses and supporting compliance with required regulations. In recent years, he has served as project principal for safety system design in lithium-ion battery manufacturing facilities across North America. Drawing on this experience, he has contributed to advancing industry standards as a principal author of the upcoming NFPA 800: Battery Safety Code and as a technical committee member for NFPA 660: Standard for Combustible Dusts and Particulate Solids. He prioritizes time with his family of five and enjoys outdoor activities such as biking, hiking and camping throughout the mountains and trails around Atlanta and elsewhere. He also volunteers as a youth basketball coach for his children’s teams, continuing a family tradition started by his father. Most importantly, Unangst aims to support health, happiness and safety in all facets of his life.
Stephen Wisniewski, PE, 33
Lead Responsible Engineer, Mechanical, Primera Engineers; BS, Mechanical Engineering, University of Wisconsin–Madison
With a decade of experience in design engineering and project management, Stephen Wisniewski collaborates with interdisciplinary teams to specify equipment selections that meet system load requirements. His expertise includes heating, ventilation and air conditioning (HVAC) system design for hydronic and airside systems, along with the layout of ductwork, piping and major equipment like pumps, boilers, condensing units and air handling units. He leverages his knowledge of codes and standards to serve as a third-party permit reviewer for major municipal building departments. He has worked on many complex projects in and around Chicago. For the Cook County Enhanced Visitation Center, he was responsible for mechanical system design that aligned with aggressive energy-performance and sustainability criteria, integrating high-efficiency HVAC systems, advanced heat-recovery strategies and optimized control sequences to minimize energy demand while maintaining strict thermal comfort requirements. Earlier in his career, Wisniewski worked on automated warehouse logistics systems and later transitioned to HVAC design and project management, coordinating permit reviews, managing project documentation and supporting capital development board projects through design and construction phases. Personal projects include volunteering with the Metro Chicago Chapter of Rebuilding Together, helping repair and renovate homes for families in need. He also mentors students and enjoys electronics projects, 3D printing and spending time with his agility dog, Spud. He and his wife welcomed a baby boy in March.
Asrar Wasay, PE, LEED AP BD+C, 30
Electrical Project Engineer, IMEG; MS, Electrical Engineering, Fairleigh Dickinson University
Asrar Wasay has nine years of experience designing large-scale building projects in New York City, with a focus on electrification, decarbonization and net-zero initiatives. At IMEG’s New York City office, he leads multidisciplinary teams on complex projects for public-sector clients, including the New York City School Construction Authority (NYCSCA). His work has contributed to award-winning projects. Since graduating, Wasay has advanced from intern to senior electrical engineer, now managing multimillion-dollar projects and serving as a key liaison with NYCSCA stakeholders. He is known for clear communication, guiding both technical and nontechnical audiences through complex design decisions. On the electrification of the 350,000-squarefoot Franklin K. Lane Educational Campus, for example, Wasay coordinated multiple agencies and extensive surveys to keep the project on track despite tight operational constraints. His technical expertise includes electrical service upgrades, load calculations, generator and emergency power systems and decarbonization-driven system redesigns that help schools transition to resilient, fully electric facilities aligned with the NYCSCA’s sustainability and decarbonization objectives. Within IMEG, Wasay mentors younger engineers and participates in technical webinars and code seminars to stay current with evolving standards. He also volunteers through alumni mentoring programs and supports community food distribution and local service efforts. Outside of work, Wasay enjoys traveling with his wife and young daughter, camping and hiking and working on cars as a creative outlet.
Alec Zimmermann, PE, 39
Principal Electrical Engineer, Zona Technical Engineering PLLC; BS, Electrical Engineering, University of Arizona
Alec Zimmermann is the co-owner and principal electrical engineer of Zona. With 12 years of experience in the consulting engineering industry, he has built a reputation for technical expertise, leadership, creativity and a strong commitment to client success. Since cofounding Zona in 2022, Zimmermann has helped establish the firm as a respected presence in the region, guiding projects and teams with a leadership style defined by sincerity, optimism and a focus on collaboration. His background includes electrical system design for primary and secondary power distribution, lighting and lighting controls, fire alarm systems and multidisciplinary coordination across complex facilities. His portfolio spans higher education, health care, commercial and government sectors. Through his work, he consistently delivers solutions that balance design innovation with reliability, cost efficiency and the operational needs of each client. In addition, Zimmermann is deeply committed to mentorship and professional growth. He oversees firm operations while supporting team members through knowledge-sharing, technical guidance and encouragement. He is also active in professional and civic initiatives, including serving on the City of Tucson Outdoor Lighting Code board and volunteering at a local food bank and numerous student outreach programs. Zimmermann’s work-life balance prioritizes time with his wife and two children. He enjoys outdoor activities such as hiking, camping, fishing, golfing and mountain biking in the Southwest. He also enjoys following his alma mater’s athletic programs at the University of Arizona.
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BUILDING SOLUTIONS
Elena Charming, PE, LEED AP, and Alexandra Linarez, EIT, SmithGroup, Washington, D.C.
How to choose a water-cooled chiller and avoid operational pitfalls
Water-cooled chillers are commonly used in the HVAC industry to provide cooling as part of a chilled water hydronic system. A full understanding of how these chillers operate and how they are affected by various design conditions can help a design engineer prevent operational issues in the field.
In many large-scale commercial buildings greater than 150,000 square feet — such as laboratories, hospitals and higher education buildings — the primary method of cooling is accomplished through the use of chillers. A chiller is a piece of equipment that utilizes refrigerant and the refrigeration cycle to create cool, or “chilled,”
water that is distributed to secondary heating, ventilation and air conditioning (HVAC) systems throughout the building.
In general, the chilled water is used in an HVAC system to cool the air in occupied spaces and “back of house” spaces, such as electrical rooms, mechanical rooms or telecommunication closets.
There are two major categories of chillers:
• Air-cooled, which rejects heat from the chiller refrigeration system to the outside air.
• Water-cooled, which rejects heat from the chiller refrigeration system to a warmer water loop, technically defined as a condenser water loop.
Though these chiller types are similar, this article will focus on the fundamentals specific to watercooled chillers and common operational issues.
In a water cooled chiller, the refrigeration cycle, driven by the compressor, absorbs heat from the chilled water loop and transfers that heat into the warmer condenser water loop where it can be rejected by downstream equipment. In general, to reject the heat absorbed by the condenser water loop from the chiller, the most common approach is to pair it with one or more cooling towers, often counterflow induced draft towers, where the upward moving air stream passes opposite the downward falling water to maximize heat transfer.
The system works by pumping warm condenser water from the chiller to the top of the cooling tower, where spray nozzles disperse the water into a fine mist, while large fans draw or blow outside air through the tower (see Figure 1). This allows for large amounts of heat to transfer from the water to the air through evaporative cooling. As some water evaporates and releases heat into the air, the remaining liquid is cooled and collected in the bot-
FIGURE 1: Example of a condenser water system diagram. Courtesy: SmithGroup
‘To transfer heat from the building chilled water loop to the condenser water, chillers rely on the thermodynamic process called the refrigeration cycle.’
tom of the cooling tower in a basin to be pumped back to the chiller.
The temperature of the condenser water supply primarily depends on the outside wet bulb temperature. Wet bulb temperature refers to the lowest temperature that can be achieved through evaporation and is generally lower than the concurrent dry bulb temperature.
For example, if it is a 95°F day, but the wet bulb temperature is 75°F, the cooling tower could cool condenser water to 80°F to 82°F because it is relying on evaporation, not conduction, to reject heat. As the wet bulb temperature decreases from a design day condition, the cooling tower leaving water temperature can also decrease if the airflow through the tower remains constant.
To transfer heat from the building chilled water loop to the condenser water, chillers rely on the thermodynamic process called the refrigeration cycle. The refrigeration cycle consists of four main parts: a compressor, condenser, expansion device and evaporator (see Figure 2).
In the refrigeration cycle, refrigerant is circulated in a closed loop system and is manipulated by the four main components to alter the refrigerant pressure and temperature throughout the cycle. The cycle can be visualized on a pressure-enthalpy (P-h) graph that plots the refrigerant’s thermodynamic properties (see Figure 3).
The bell-shaped curve in the middle of the graph represents the saturation curve. A state point to the left of the curve is considered a fluid, a state point to the right of the curve is considered a vapor and any point within the curve is considered a fluid-vapor mixture. In most P-h graphs, constant temperature lines are overlaid onto the graph. To the left and right of the curve, temperature generally decreases as enthalpy decreases. However, within the saturation curve temperature remains constant with the pressure as enthalpy
FIGURE 2: Line diagram of the refrigeration cycle. Courtesy: SmithGroup
FIGURE 3: Example of a refrigerant pressure-enthalpy (P-h) chart with the refrigeration cycle overlaid. Courtesy: SmithGroup
increases or decreases.
The evaporator has the lowest operating pressure and temperature in the refrigeration cycle, with the inlet and outlet points represented by state points 1 and 2, respectively, in Figure 3. The evaporator acts as a heat exchanger with the building’s chilled water system, such that as refrigerant enters the evaporator it absorbs heat from the chilled water system, resulting in the refrigerant becoming a vapor as it leaves the evaporator.
In a perfect refrigeration cycle, state point 2 falls exactly on the saturation curve, but to protect the compressor from unwanted liquid, the state point is usually designed to be “super-heated” into the vapor region of the graph. After the evaporator, the vaporized refrigerant enters the compressor, where work is added to the cycle to increase the vaporized refrigerant’s pressure and temperature to state point 3. At this elevated temperature, the refrigerant enters another heat exchanger called the condenser where heat is taken out of the refrigerant and absorbed by the condenser water loop.
• Understand how the refrigeration cycle operates in the context of watercooled chillers.
• Learn about common operational issues that can happen at part-load and winter conditions.
• Identify several design solutions that can help mitigate operational issues.
BUILDING SOLUTIONS
At the outlet of the condenser, the refrigerant is a high-pressure liquid. Like state point 2, in a perfect refrigeration cycle, state point 4 would fall on the saturation curve, but typically the refrigerant is “sub-cooled” past the saturation curve to ensure only liquid is sent onward in the cycle. The last device, the expansion valve, reduces the pressure and temperature of the refrigerant back to state point 1 to start the cycle over again.
Chiller compressor types and function
There are several different types of compressors that can be used within a water-cooled chiller. Within the HVAC industry, the four most common types of compressors are reciprocating, scroll, screw and centrifugal. Each compressor type has a unique way of compressing the refrigerant vapor.
• Reciprocating compressors use pistons for compression and are best suited for small tonnage applications typically 200 tons or less.
• Scroll compressors operate by rotating two interlocking spirals and are generally best for small tonnage applications — 200 tons or less — where a quieter operation is desired.
• Screw compressors use two interlocking helical screws and are best suited for medium to large tonnage applications ranging 100 to 500 tons.
• Centrifugal compressors operate by rotating
the vapor with an impeller at high speeds to increase the velocity, which is then sent through a diffuser that slows down the vapor and increases the pressure. Centrifugal compressors are generally most appropriate for large tonnage applications that are 300 tons and greater.
All of these compressor types, except for certain magnetic bearing centrifugal compressors, which use magnetic fields to levitate the rotating shaft and therefore operate without traditional oil lubricated bearings, require constant oil lubrication mixed with the refrigerant vapor to prevent mechanical damage.
Some of the fundamental functions of oil in a compressor are to lubricate the moving parts, seal gaps in the compressor between high- and low-pressure areas and absorb heat created by friction. In the compressor, the oil is sprayed into a fine mist, which is carried along with the high-pressure refrigerant vapor, eventually entering the condenser and mixing with the refrigerant liquid as the refrigeration cycle continues.
Oil in standard commercial refrigerants is miscible at higher temperatures, but as the temperature drops, oil and refrigerant are likely to separate. In addition, oil does not vaporize at the same temperatures as common refrigerants, meaning as the refrigerant vaporizes in the evaporator, the oil will remain a liquid.
If no means of oil return is implemented, the liquid oil will then sit in the evaporator and not return to the compressor. This will not only cause a reduction in heat transfer at the evaporator, but it will also cause the compressor to fail due to low oil. To prevent this, chillers are designed with oil return systems to capture the oil and return it to the compressor (see Figure 4).
Oil return systems vary depending on the manufacturer, but in general an oil separator is used at the outlet of the compressor to capture most of the liquid oil in the refrigerant vapor. The oil is then collected from the separator, cooled or heated to maintain proper temperature and then typically pumped through a filter back to the compressor.
However, oil separators are never 100% efficient, so some oil will still move through the components and reach the evaporator. If no solution to returning oil from the evaporator is implemented, then overtime the low oil issue described above will occur.
FIGURE 4: The refrigeration cycle diagram with an oil return system.
Courtesy: SmithGroup
A common method to return oil from the evaporator is done by leveraging the pressure difference between the condenser and the evaporator. To do this, a small amount of high pressure-refrigerant vapor from upstream of the condenser is passed through an eductor, which is a venturi-style nozzle that also has a connection to the low-pressure evaporator. When the high-pressure vapor passes through the eductor, the venturi effect provides suction on the line connected to the evaporator. The oil then travels through this line and is combined into the oil return system.
Operational pitfall: head pressure
A key operational challenge for water cooled chillers during seasonal low load conditions is maintaining adequate head pressure, particularly as condenser water temperatures drop in winter. Most water cooled centrifugal chillers are designed with a minimum entering condenser water temperature requirement, which ensures the chiller maintains
Courtesy: SmithGroup
sufficient lift, the pressure difference between the evaporator and condenser, to properly move refrigerant through the cycle.
FIGURE 5: Depiction of lower condenser water supply temperature lowering the condenser operating pressure on a pressure-enthalpy (P-h) chart.
BUILDING SOLUTIONS
FIGURE 6: Condenser water system diagram with design day and lowload operating points. Courtesy: SmithGroup
‘
Even without the evaporator freezing, if the condenser water flow and cooling tower airflow remain constant, the condenser water will continue to reject heat at the same rate, despite the low evaporator load.
When condenser water temperatures fall below this minimum threshold, the chiller may struggle to maintain the necessary pressure differential, leading to unstable refrigerant management, reduced capacity, erratic compressor loading, or even nuisance safety trips. In extreme cases, excessively low condenser water temperatures can cause refrigerant migration, premature surge conditions or evaporator temperature collapse, all of which jeopardize reliable chiller operation.
For these reasons, careful control of cooling tower fan speed, condenser water flow and any applicable bypass strategies becomes essential during winter and other low load periods to keep the condenser water temperature within the chiller’s allowable operating envelope and maintain stable, efficient performance.
As pressure and temperature are directly related within the saturation curve, lift can be defined as the difference between entering condenser water temperature and leaving chilled water temperature. If a chiller is used for comfort cooling in a building, the capacity and lift will generally be sized for a peak summer cooling condition.
However, in actual operation for most of the year, the chiller will be in a part-load condition. For example, when the outdoor air temperature decreases, there is less heat gain through the building envelope, so the load on the evaporator from the building decreases.
Meanwhile, the ambient wet bulb temperature will also likely decrease, causing the condenser water supply setpoint through the cooling towers to decrease proportionally with it. A lower condenser water supply temperature lowers the overall lift the chiller needs to achieve. A reduction in lift corresponds to a reduction in pressure differential between the evaporator and condenser, meaning the amount of work the compressor is required to add to the system can significantly decrease (see Figure 5).
The reduction will increase the energy efficiency of a chiller until a point where the head pressure is not sufficient to keep the refrigerant flowing from the condenser to the evaporator. At this point, the refrigerant may become unstable and flow backwards through the refrigeration cycle, which can cause significant damage to the compressor.
Another issue that can be caused by low head pressure is insufficient oil return to the compressor. Many chiller designs rely on the pressure differential between the evaporator and condenser, as described above, to return accumulated oil in the evaporator. When the condenser pressure begins to decrease too far, the vapor sent to the eductor will not be sufficient to create enough suction. Without suction, the oil will begin to accumulate in the evaporator and cause the chiller to shut down to protect the compressor from damage.
Operational pitfall: low load
In tandem with issues related to condenser water and head pressure control, maintaining enough load on the evaporator side of the refrigeration cycle is crucial to prevent damage to the chiller. If the evaporator is in a low load condition, the refrigerant does not pick up enough heat to fully vaporize at the design pressure, which can cause the operating pressure and associated temperature in the evaporator to drop below freezing (32°F) to achieve full vaporization. At this point, the chilled water entering the chiller will begin to freeze upon contact with the coils in the evaporator and prevent any heat from being exchanged, causing the refrigerant to remain a liquid. When this occurs, the chiller will shut down to prevent damage to the compressor due to insufficient refrigerant flow from the evaporator.
For example, Figure 6 depicts a 300-ton watercooled chiller that is designed to handle comfort cooling and electrical room loads. The electrical room cooling loads are calculated to be 30 tons, the chilled water to the building supplies 720 gallons per minute (gpm) at 45°F with a 15°F differential and the condenser water to chiller is supplied 900 gpm and 85°F with a 10°F differential.
During late fall or early spring, represented in Figure 6 as blue state points, it is likely that the only cooling load remaining on the chiller would be the electrical rooms, which is 10% of the overall load. At this low-load condition, the amount of heat rejected to the evaporator from the building may be insufficient to prevent freezing of the evaporator coil. Even without the evaporator freezing, if the condenser water flow and cooling tower airflow remain constant, the condenser water will continue to reject heat at the same rate, despite the low evaporator load.
Considering this, the condenser water supply temperature will quickly drop from 85°F toward the low-ambient winter wet bulb temperature. Generally, if the lift reaches 15°F or less, in this case when the condenser water temperature reaches 60°F, issues due to low head pressure will start to occur.
A solution to protecting the evaporator in the low-load scenario described is to select a chiller with a hot gas bypass function. The availability of hot gas bypass should be coordinated with the manufacturer before specifying this approach.
Hot gas bypass is an additional component in the refrigeration cycle that allows artificial loading of the evaporator when there are low loads from the building. When hot gas bypass is enabled, the compressor will respond to the artificial load and consume more energy than what would be required to meet only the building load. The hot gas bypass is a connection between the compressor and inlet of the evaporator by means of an automatic or manual pressure reducing valve (see Figure 7).
The pressure reducing valve is designed to provide constant pressure to the inlet of the evaporator, artificially increasing the evaporator’s overall pressure and temperature to a stable operating condition. This allows the chiller to satisfy low building loads by bypassing some of the work added to the system by the compressor directly to the evaporator.
However, with this solution the lift and head pressure control on the condenser side becomes a critical issue as even less heat is sent to the condenser to be rejected by the cooling towers.
Methods for chiller head pressure control
There are several solutions to maintain head pressure control in a chiller and effective control comes from careful consideration of how the condenser water system operates. If the cooling towers are designed with variable frequency drives (VFDs), then as the ambient wet bulb temperature decreases, the cooling tower fan speeds can reduce to limit the airflow through the tower. With less air
7: The refrigeration cycle with hot gas bypass. Courtesy: SmithGroup
FIGURE
‘
BUILDING SOLUTIONS
There are several solutions to maintain head pressure control in a chiller and effective control comes from careful consideration of how the condenser water system operates.
to evaporate into, the condenser water will reject less heat than on the design summer day.
However, at some point, any amount of airflow through the cooling towers may still cause too much heat rejection to match a low building load condition. To further reduce unwanted heat transfer, the condenser water pumps are recommended to be designed with VFDs to reduce the condenser water flow to a specified minimum.
This minimum flow should be coordinated with the chiller manufacturer’s prescribed minimum flow rate. Manufacturers will dictate minimum flow rates through the condenser to ensure that water remains turbulent and not laminar through the coils. Laminar flow greatly decreases heat transfer in a heat exchanger and may cause insufficient condensation of refrigerant, leading to negative impacts on the refrigeration cycle.
In addition to VFDs, incorporating two condenser water bypasses with motorized valves provides full control of the condenser water supply setpoint and, therefore, lift. The first bypass recommended is around the cooling tower and directly into the cooling tower basin. When this bypass is active, the tower fans can be off, allowing the water to be diverted directly to the basin to exchange relatively small amounts of heat through conduction with the cold outside air. This bypass helps limit heat transfer but still does not give the system complete control over the condenser water supply temperature.
are designed to manage it. Typically to manage this head pressure issue, a second condenser-water bypass between the supply and return, commonly found inside the mechanical room, is recommended. During switchover, the condenser water bypass valve is commanded fully open, while all cooling tower motorized isolation valves are driven fully closed. This strategy minimizes the volume of excessively cold condenser water that the chiller must warm up by limiting it to the water contained only within the indoor mechanical room piping, rather than the entire cooling tower loop.
By reducing this thermal mass, the entering condenser water temperature rises more quickly, allowing the chiller to reestablish proper lift and exit inverted mode safely. Without such control, the chiller would struggle to maintain the necessary head pressure, significantly increasing the risk of liquid refrigerant flooding back into the compressor, leading most chillers to shut down automatically to prevent damage.
Designing a high-performance water-cooled chiller plant requires a holistic approach that anticipates all operating scenarios, from peak summer loads to the most challenging off season low-load conditions. All major equipment, including chillers, cooling towers, pumps and heat exchangers, must be sized for both maximum demand and stable, reliable operation at minimum anticipated loads and ambient temperatures.
csemag.com
Chiller insights
u A chiller is a key component in large commercial HVAC systems, using the refrigeration cycle to remove heat from chilled water that cools building spaces and transferring that heat to a condenser water loop that rejects it through cooling towers.
u Proper chiller operation requires careful control of lift and head pressure — especially during lowload or cold-weather conditions — to prevent issues such as unstable refrigerant flow, poor oil return, evaporator freezing or compressor damage.
For example, during a system start up, condenser water that has been sitting stagnant in a cooling tower basin and exterior piping will likely be close in temperature to the ambient outdoor conditions. If it is 55°F outside and the condenser water system is enabled, the cooling tower bypass will not be able to prevent the 55°F condenser water from entering the chiller before it has reached stable operation.
Most centrifugal chiller manufacturers guarantee limited operation — typically less than 15 minutes — in inverted mode, which is a temporary condition in which the condenser water temperature falls below the chilled water temperature while the chiller is operating. When this happens, refrigerant flow can become unstable due to issues with head pressure.
Inverted mode is not only predictable but expected during the transition from waterside economizer to mechanical cooling and modern building automation system (BAS) sequences
Reliable chiller operation depends on precise head pressure and lift control, achieved with VFDs on tower fans and pumps and proper minimum flow rates. Robust bypass and isolation valve strategies are essential for managing transitions, especially during economizer switchover and inverted mode, while ensuring the BAS anticipates and limits time in these conditions. Hot gas bypass and continuous BAS monitoring are critical for lowload safety. Lastly, all control sequences must be thoroughly commissioned and validated under simulated low-load and low-ambient scenarios to ensure reliable, year-round performance. cse
Elena Charming, PE, LEED AP, is a mechanical engineer at SmithGroup.
Alexandra Linarez, EIT, is a mechanical engineer at SmithGroup.
Twenty-five years ago, Hammond Power Solutions began as a new chapter in the 100-year legacy of the Hammond
We’d like to thank our customers for the opportunity to collaborate and for the trust you've placed in us over the years, helping HPS grow into one of North America’s largest manufacturers of dry-type transformers.
We look forward to building a more efficient and reliable energy future together, one that will power progress around the
BUILDING SOLUTIONS
Jarron Gass, PE, CFPS, CDM Smith, Pittsburgh
How to conduct fire hydrant flow testing
Fire hydrant flow testing provides an overview of the water supply and availability within a public distribution system, with test data used to guide fire departments when developing response strategies and drive decision-making regarding fire protection and other engineering disciplines.
Buildings and facilities served by public or private water distribution systems require a fundamental component of fire protection and water infrastructure design — fire hydrant flow testing. Hydrant flow testing is routinely required where an underground water distribution system exists, to establish the available water supply for fire sprinkler systems, standpipe systems, fire hydrants and manual firefighting operations. The data obtained from these tests form the empirical basis for evaluating system feasibility, regulatory compliance and overall fire protection reliability.
Hydrant flow testing is also considered during plan review, permitting and acceptance testing to demonstrate that minimum fire flow and pressure requirements are satisfied. When properly performed and interpreted, flow testing provides a defensible, real-world assessment and validation of water system performance that cannot be replicated through theoretical calculations alone.
Fire hydrant flow testing codes and standards
NFPA 13: Standard for the Installation of Sprinkler Systems specifies the primary standard governing water supply requirements for fire sprinkler systems. Additional NFPA standards establish water supply criteria for residential sprinkler systems (NFPA 13R and NFPA 13D), standpipe and hose systems (NFPA 14: Standard for the Installation of Standpipe and Hose Systems) and specialty suppression systems such as foam-water and water mist systems. Each standard relies directly or indirectly on accurate knowledge of available water flow and pressure.
• Understand the fire hydrant flow testing process.
• Know the key reasons to conduct fire hydrant flow testing.
• Learn how to analyze flow test results.
Fire protection engineers and contractors rely on hydrant flow testing to assess whether the existing water supply can support the required fire protection demands under emergency conditions. Plumbing and civil engineers use the results similarly to design underground mains, hydrant laterals and building services that supply both fire protection and potable water systems. Because water supply characteristics directly influence hydraulic performance, hydrant flow testing represents a critical early input to engineering design and project decision-making.
Although final system demand is determined through detailed hydraulic calculations, factors such as anticipated hazards, required discharge densities, minimum end-head pressures, elevation changes and pipe friction losses allow designers to estimate water supply needs early in the design process. Hydrant flow testing refines these estimates by providing measured values that reflect actual system performance.
Some buildings and facilities are not required to be equipped with a sprinkler system. However, both the International Fire Code (IFC) and NFPA 1: Fire Code establish minimum water supply requirements for manual firefighting operations. These requirements are generally based on construction type, fire area, occupancy classification and required fire flow duration. In these
HYDRANT flow testing provides valuable input data for the development of water infrastructure, assisting in community planning. In this setup, the diffuser is attached to a hydrant outlet and directs discharged water away from the hydrant. The diffuser enables high-volume flow to be released safely even in constrained or landscaped areas. Courtesy:
cases, hydrant flow testing provides the data necessary to determine whether the available water supply can support firefighting operations without reducing system flow and pressure below acceptable thresholds.
Role of fire hydrant flow testing in engineering design
Accurate water supply data are essential for determining the proper sizing of fire protection system components, including underground piping, fire pumps, backflow preventers, control valves and system risers. Civil engineers rely on hydrant flow test results to size distribution mains and service connections supplying hydrants and buildings, while plumbing engineers use the same data to evaluate domestic and process water demands.
Errors or uncertainty about available flow and pressure assumptions can have significant consequences. Underestimating available supply may lead to unnecessary fire pumps or storage tanks, thereby increasing construction and operational costs. Overestimating supply can result in systems that fail to deliver required performance during an emergency. Hydrant flow testing therefore serves as a critical risk-reduction tool by grounding hydraulic design in measured field conditions rather than assumptions or historical records.
Fire hydrant flow testing standards and methodology
Governing standard: The primary reference for hydrant flow testing procedures is NFPA 291: Recommended Practice for Fire Flow Testing and Marking of Hydrants. Flow testing determines the available water supply at a specific location and time and identifies potential system deficiencies, such as excessive friction loss, partially closed valves or constrained distribution mains.
Flow testing does not establish absolute system capacity under all operating conditions. Instead, it provides a brief overview of system performance that must be interpreted within the context of known variability, including changes in demand,
FIRE
CDM Smith
A HYDRANT PITOT pressure gauge measures flow pressure at the hydrant outlet during fire hydrant flow testing. Courtesy: CDM Smith
FIGURE 1: Typical fire hydrant flow test arrangement. Courtesy: CDM Smith
BUILDING SOLUTIONS
A handheld Pitot is used to obtain flow pressure during fire hydrant flow testing. Courtesy:
seasonal usage patterns, infrastructure condition and operational controls.
Test configuration: A typical flow test involves at least two hydrants:
• One test hydrant for taking pressure measurements
• One or more flow hydrants for discharging water to create flow conditions
The test hydrant is generally located upstream of the flow hydrant(s) to ensure that measured pressures reflect overall system behavior rather than localized losses (see Figure 1).
Table 1: Example hydrant flow test results and calculated fire flow
Test procedure: The procedure begins by attaching a calibrated pressure gauge to the test hydrant to measure static (nonflowing) pressure. One or more flow hydrants are then fully opened and a Pitot gauge or calibrated flowmeter is used to measure nozzle pressure at the point of discharge. While water is flowing, the residual (flowing) pressure is recorded at the test hydrant.
Flow is calculated using the NFPA 291 equation:
Q = 29.83 × C × d 2 × √p
where Q is the flow rate in gallons per minute (gpm), C is the discharge coefficient accounting for outlet geometry and friction loss, d is the nozzle diameter in inches and p is the Pitot pressure in pounds per square inch (psi).
Available flow at 20 psi residual pressure: NFPA 291 provides a standardized method for estimating available flow at a residual pressure of 20 psi. This pressure is widely accepted as the minimum residual pressure at hydrants for effective firefighting operations and is generally the lowest pressure to which water purveyors permit the system to be drawn during emergency use.
Calculating available flow at 20 psi allows engineers to compare measured supply against code-required fire flow and system demand under consistent conditions (see Table 1).
Interpretation and engineering judgment
Hydrant flow test results are typically used to develop water supply curves that relate flow to residual pressure. These curves are compared against system demand curves during hydraulic analysis to determine whether the available water supply meets or exceeds required fire protection demands (see Figure 2).
TABLE 1: Values shown are illustrative only based on a 4-inch diameter and discharge coefficient of 0.57. Calculated flow depends on nozzle size, discharge coefficient and measured Pitot pressure. Courtesy: CDM Smith
Engineering judgment is required when interpreting test results. Flow test data must be evaluated in the context of expected operating conditions, including peak domestic demand, seasonal variability, storage tank levels and pump operating modes. Where required by the authority having jurisdiction (AHJ) or water purveyor, additional safety factors may be applied to account for uncertainty, aging infrastructure or future system modifications.
CDM Smith
Engineering disciplines benefiting from fire hydrant flow test data
While hydrant flow testing is predominantly associated with fire protection engineering, the data obtained from these tests are valuable to multiple engineering disciplines involved in building and infrastructure design.
Civil engineering: Civil engineers use hydrant flow test results to size water distribution mains, evaluate system capacity for future development and assess the adequacy of existing infrastructure. Degrading test results over a period may reveal deteriorating pipe conditions as well. Flow and pressure data support decisions related to pipe diameters, looping strategies and redundancy in municipal or private water systems. In land development and campus planning projects, flow testing provides empirical input for determining whether off-site water system improvements are required.
Plumbing engineering: Plumbing engineers rely on water supply data to evaluate domestic water pressure availability, booster pump requirements and pressure zoning strategies in multi-story buildings. Hydrant flow testing helps identify wheth-
2: Typical water supply curve derived from hydrant flow test data. Courtesy: CDM Smith
er domestic systems can operate without excessive pressure loss during fire events and informs coordination between fire protection and potable water systems sharing common supply piping.
Structural engineering: Although structural engineers do not directly design water systems, hydrant flow data can influence
‘Measured flow test data provide a valuable basis for validating and calibrating hydraulic water distribution models.’
structural design decisions related to fire protection infrastructure. The need for fire pumps or large on-site water storage tanks affects equipment loads, flooring penetrations, seismic bracing and foundation design. Early knowledge about water supply limitations allows these considerations to be integrated more efficiently into the structural design.
Mechanical engineering and process design: Within industrial, laboratory and utility facilities, mechanical and process engineers use water supply data to assess whether available flow and pressure can support cooling systems, process water demands or emergency deluge systems. Hydrant flow testing provides baseline data for evaluating simultaneous demand scenarios involving fire protection and critical process systems.
Fire hydrant flow testing: Modeling, timing and frequency
Measured flow test data provide a valuable basis for validating and calibrating hydraulic water distribution models. By comparing modeled predictions with measured results, engineers can adjust assumptions to better reflect real-world system behavior. Validated models support future development planning, infrastructure upgrades and longterm capital improvement programs.
Conducting hydrant flow testing early in the design process improves coordination among fire protection, civil, plumbing and structural disciplines. Early identification of water supply constraints allows for informed design decisions before detailed layouts or contractor procurement begin. This approach improves bid quality, reduces change orders and leads to more predictable project results.
NFPA 13 also requires another hydrant flow test within 12 months of the submission of shop drawings of a fire sprinkler design to confirm fire flow supply adequacy, if the initial hydrant flow test was conducted earlier than the 12-month threshold.
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Fire hydrant flow testing insights
u Fire hydrant flow testing provides the empirical foundation for fire protection design, translating measured static, residual and Pitot pressures into defensible water supply curves that guide code compliance, system sizing and risk reduction.
u Beyond fire protection engineering, hydrant flow test data inform multidisciplinary decisions from civil main sizing to structural pump loads and can uncover hidden infrastructure changes that directly affect system reliability.
Urban planning and infrastructure management: For municipalities and large property owners, hydrant flow test results contribute to broader infrastructure management efforts. Planners and asset managers use the data to prioritize capital improvements, evaluate system resilience and support long-term growth planning. When integrated into hydraulic models, flow testing results enhance confidence in planning-level analyses.
Coordination, safety and documentation
Hydrant flow testing must be coordinated with the water purveyor and AHJ to minimize service disruptions and pressure effects on adjacent users. Testing activities require careful planning to address traffic control, erosion prevention and safe discharge of high-velocity water.
All test results should be thoroughly documented, including hydrant locations, test dates, equipment used, measured pressures, calculated flows and ambient conditions. In some jurisdictions, hydrants must be marked or color-coded (based on performance characteristics) in accordance with NFPA 291 or local amendments.
In addition to project-specific testing, many water purveyors perform periodic hydrant flow testing as part of system maintenance programs. Engineers should verify the age and applicability of available test data, as system conditions may change significantly over time.
Fire hydrant flow testing is a critical component of fire protection and water system design that provides empirical data about available flow and pressure under real-world conditions. Accurate and properly interpreted test results support code-compliant, reliable and cost-effective design of sprinkler systems, standpipes, hydrants and potable water infrastructure.
Beyond fire protection engineering, hydrant flow test data support informed decision-making across multiple engineering disciplines, including civil, plumbing, structural and mechanical engineering. When conducted in accordance with NFPA 291 and integrated early into the design process, hydrant flow testing provides a robust technical foundation for resilient and coordinated infrastructure design. cse
Jarron Gass, PE, CFPS, is a Fire Protection Engineer at CDM Smith, Pittsburgh.
PUT YOUR LIFT STATION ON AUTOPILOT
How one Midwest town is winning against modern flushables
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serving a regional hospital, county jail, and landfill, they installed a Pentair Hydromatic® HPS Series Next-Gen Pump.
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BUILDING SOLUTIONS
Christopher Unangst, PE, CSP, PMP, Jensen Hughes, Atlanta
Know the risks involved in designing EV charging stations
The charging of electric vehicles (EVs) presents challenges and emerging considerations. Learn the risks associated with charging and the safety measures to address those risks.
IObjectives
• Learn the basics of electric vehicle (EV) charging.
• Understand the electrical risks of EV charging.
• Identify safety measures to take to mitigate risk.
n 2007, the electric vehicle (EV) boom had not taken hold yet. With just 139 public EV charging stations in the United States, EVs, let alone charging infrastructure, were still in early adoption. It wasn’t until 2011 when EV charging stations started to proliferate.
According to the U.S. Department of Energy, as of 2023, at least 64,641 EV charging stations and 168,388 charging ports were operational — a 500fold increase in less than two decades. The infrastructure to provide energy to the vehicles that move us throughout the world is still catching up to the widespread adoption of EVs.
Globally, as of 2025, there are 5.45 million publicly available charging ports. At this stage in the
development and adoption of EVs and supporting infrastructure, based on the rapid expansion of adoption and infrastructure, one can be forgiven for assuming that EV charging hazards are well understood and thoroughly regulated.
However, the regulatory framework is still very much evolving and, like infrastructure, has been playing catchup for the past 10 years.
EV charging process
EVs fundamentally change how energy is delivered to vehicles. Unlike internal combustion engines (ICE), which are fueled with fossil fuels (gasoline/diesel) transported to gas stations by tanker trucks, charging stations for electric vehicles are typically connected directly to the power grid (see Figure 1). Energy from the grid is transferred to EVs by means of power conversion (if necessary), charging ports and a connector. Components of the charging system are commonly referred to as electric vehicle supply equipment. The EV “fueling” process is compared to the analogous process for ICE vehicles in Figure 2.
Power grid: Electricity comes in two forms: alternating current (AC) and direct current (DC). AC is an oscillating voltage that continually reverses polarity in a smooth wave appearing as a sine graph, completing one oscillation in 1/60 of a second. DC provides a constant voltage to the user and does not change polarity.
Most energy transmission within a power grid is supplied with AC electricity. Energy providers use AC because it is easier to transport over long distances as Westinghouse demonstrates in the 1900s, owing to its inherent properties (constantly changing voltage). Batteries provide DC voltage and hence EV batteries are recharged using DC electrical power but is limited in its ability to travel over long distances.
Power conversion: Power conversion is one of the main components of EV charging, translating the
Courtesy: Adobe Stock
grid’s AC electrical power into the appropriate DC voltage and current to charge the EV’s battery. The power conversion components can consist of a transformer, switchgear, AC/DC converter and control circuitry, dependent on the power supply and the level of charger.
The primary function of a transformer is to adjust the transmission or distribution voltage to the appropriate use voltage on the facility. A transformer can either increase or decrease voltage. When connecting directly to a power grid, it is common to decrease the voltage to the desired use value. Transformers use electromagnetic induction consisting of a primary winding, secondary winding and magnetic core. The transformer is then connected to electrical distribution equipment, such as switchgear, distribution boards or cables, to distribute the energy to the load.
In charging systems, the conversion of AC power to DC is typically done with a switch-mode power supply. A switch-mode power supply works by converting the AC power to raw DC through rectifiers, using the frequency of the AC energy to rapidly turn the AC wave on and off ching to efficiently convert that power to the voltage the charging circuit needs.
Fast charging (via Level 3 chargers) requires DC electricity; for Level 1 and 2 charging, EVs have a built-in AC/DC converter, which is also known as an on-board charger and allows for an AC electrical supply. Power conversion equipment will typically be contained in an enclosure. The enclosure safeguards the electronics and electrical equipment from environmental factors, such as rain, snow, dust or debris (NEMA 3R, NEMA 4X, IP67, etc.) and also designed to dissipate the heat created by the conversion process.
Charging stations and ports: A charging station is a physical location that provides one or more EV charging ports, typically found in parking garages or parking lots. These stations include control equipment that manages the charging process by commu-
nicating with the connected vehicle to ensure power is delivered at the right speed. An EV charging port provides power to charge one vehicle at a time. The unit that houses EV charging ports is sometimes called a charging post, which can have one or more EV charging ports. Most charging stations include a user interface, which can range from simple indicator lights to advanced touchscreens that display charging status, power usage and other operational details.
EV charging stations
Charging stations are grouped into different categories, based on the voltage provided to the EV — currently grouped into one of the following:
Cable and connector: Charging cables need to handle significant currents while maintaining flexibility for maneuverability and ease of use. Generally, the thickness varies by charging level, with thicker cables required to support higher amperage (greater the charger level, thicker the cable). The cable extends from the charging port and ends in a connector, which plugs into the electric vehicle.
The design of the connector varies by the standards it supports; standards include Society of Automotive Engineers J1722, International Electrotechnical Commission (IEC) 62196, North American Charging Standard, Combined Charging System or CHArge de Move (“charge and go”). Some connectors support only AC charging (Level 1 and 2) while others support DC fast charging. In addition to power transfer, cables and connectors must carry communications signals between the charging station controller and EV (see Figures 5 to 9).
Electric vehicles: EVs can include many different modes of transportation, including a wide range of cargo trucks (18-wheelers), passenger automobiles, recreational craft (boats) and even micro-mobility devices (e-bikes/scooters). This article’s focus is on automobiles inclusive of various classes such as compact cars, sport utility vehicles (SUVs), trucks and
‘The power conversion components can consist of a transformer, switchgear, AC/ DC converter and control circuitry, dependent on the power supply and the level of charger.’
FIGURE 1: Process flow diagram for internal combustion engine vehicle fueling. Courtesy: Jensen Hughes
FIGURE 2: Process flow diagram for electric vehicle charging. Courtesy: Jensen Hughes
BUILDING SOLUTIONS
commercial fleets (buses, delivery trucks, etc.).
The two primary types of vehicle electrification using charging are battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs). Typical components of a BEV include an electric motor, battery pack, power inverter, DC/DC converter and a port for the connector to charge. A PHEV contains the same components as a BEV, however the battery pack stores less energy and it is equipped with an engine that runs on gasoline.
The battery pack consists of numerous physically connected modules that store energy supplied to the electric motor when required. Each module contains battery cells, physically connected to one another. The resulting battery pack voltage can range anywhere from 200 to 800 volts (V) in contemporary EVs. The battery pack has an integrated battery management system to ensure proper operation during storage, discharging and charging.
cuits, damaged cables, faulty charging equipment, electrical surges, overheating of the charging equipment (e.g., when the battery is charged too rapidly), improper use and maintenance of the charging equipment or lightning strikes.
The charging stations themselves do not significantly change the fire risk in terms of fire load, while it is known that fully charged batteries have more energy to release in fire scenarios. Research has shown that the risk of starting thermal runaway is increased during charging operations. While charging, the battery is in an electro-chemically active state and electrical energy is being supplied into the system. As a result, the risk of fire initiated by the EV battery is higher in charging areas than in other parking areas. Failure inside the battery can occur because of the charging process without being visible from the outside; failures and consequences may not be immediately recognized as EVs are often unattended during charging.
The risk may change as the number of charging stations increases in a single area and start to age in service. In general, the greater the number of chargers, the greater the overall likelihood of failure. Similarly, the likelihood of failure may increase with age, especially for systems not properly maintained per manufacturer instructions.
‘Research has shown that the risk of starting thermal runaway is increased during charging operations.’
The battery pack is typically contained along the length and width of the car between the front and rear wheels, under the floor. This high-voltage battery is different from a vehicle’s 12-V battery that powers lighting and instrumentation systems. A DC/ DC converter allows the high voltage vehicle battery pack to provide power to the 12-V system.
Typical EV motors are powered by AC electricity. As the battery pack stores DC, a power inverter between the battery pack and motor allows energy to flow between the battery and the electric motor.
Risks of EV charging
When discussing risk, it is important to understand that risk is a product of likelihood and severity of hazardous events. In this section we will discuss topics that affect both the likelihood and severity of events.
Initiating cause frequency (likelihood) x event severity (consequence) = Risk
Likelihood: Thermal events at charging stations can occur due to electrical malfunctions, short cir-
Consequence: EV fires are comparable to ICE vehicle fires when comparing characteristics such as fire load, fire intensity and smoke production. (Research and testing on single passenger vehicle fires have yielded peak heat release rates of 20 megawatts — a maximum fire size comparable across ICE vehicles and EVs.) There are other characteristics of battery fires that are unique to EVs: they are difficult to extinguish and can unexpectedly reignite — sometimes hours after visible signs of products of combustion have receded. Thermal events may also include the release of flammable/ toxic/corrosive gases. Depending on the initial configuration of EVs, heat released in fire scenarios can easily cause multivehicle fires.
Charging stations in parking garages presents unique hazards. Parking spaces are generally becoming smaller, while the vehicles are becoming larger (e.g., SUVs), resulting in smaller separation distances between vehicles which promotes fire spread between vehicles. Sprinkler systems (if provided) are intended to contain the fire, protect the building and increase life safety until fire services arrive.
FIGURE 3: Station with electric vehicle charging ports. Courtesy: Jensen Hughes
Furthermore, sprinklers protect adjacent vehicles by inhibiting fire spread, limiting temperatures and heat radiation to protect load-bearing structural elements (ceiling, pillars, walls) and shorten recovery time afterward. A significant portion of existing parking garages within the United States, particularly open parking garages, are not sprinkler-protected.
Charging stations in open air, surface level parking lots allow for ease of access during a thermal event. However, if charging stations are located on exterior walls of buildings or near buildings, a fire originating near the charging station may serve as a hazard to the nearby structures. If a thermal event was to occur, the location may affect the severity of that event.
Safety measures for EVs
Many industry organizations and governing bodies provide requirements on how to safely install and operate an EV charging station. IEC publishes both IEC 61851-1 and IEC 62196-1. IEC 61851-1 applies to EV supply equipment for charging electric road vehicles. IEC 62196-1 applies
to EV plugs, EV socket-outlets, vehicle connectors, vehicle inlets (herein referred to as “accessories”) and cable assemblies for EVs intended for use in conductive charging systems.
In the United States, the NFPA 70: National Electrical Code (NEC) also provides requirements for the installations of charging equipment, including detailed requirements on wiring, ventilation, protection against overcurrent and emergency disconnects. The International Building Code (IBC) references the NEC for installation requirements. Both the
FIGURE 4: Electric vehicle charging station levels. Courtesy: Jensen Hughes
BUILDING SOLUTIONS
u FIGURES 5-9: Connector types for electric vehicle charging stations.
Courtesy: Jensen Hughes
NEC and IBC reference UL listed and labeled components of charging stations. The critical UL listings include both UL 2022: Standard Testing for EV Battery Chargers and UL 2594: Electric Vehicle Supply Equipment. Listed equipment ensures that the equipment has been evaluated and tested for quality and safety.
There are both preventive and mitigative measures to address EV and charging station hazards.
Insights
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EV charging insights
• As EV charging infrastructure has expanded from a handful of grid-connected installations to tens of thousands of power conversion systems nationwide, electrical engineering considerations — such as transformer sizing, switchgear protection, AC/DC conversion, load management and fault mitigation — have become central to safe and reliable deployment.
• Although EV charging is now widespread globally, with millions of public ports in operation, the hazards, regulatory frameworks and mitigation strategies associated with EV charging continue to evolve alongside the technology and its accelerating deployment.
Preventive measures include:
• Ensure the EV charging stations and associated equipment meet minimum quality manufacturing standards such as ANSI/UL 2202: DC Charging Equipment for Electric Vehicles. Equipment meeting these standards can be identified by the certifications provided with the product or by markings/labels on the product itself.
• Minimize fire risk, it is important for charging station operators and manufacturers to follow local standards and guidelines for electrical and fire safety, as well as conducting regular maintenance and inspections of the charging equipment.
• Establish guidelines for users on how to handle equipment and charge EVs.
• Prohibit combustible materials such as gasoline, oil, chemicals, vegetation, wood or cardboard near charging station locations.
Mitigative measures include:
• Provision of a fire services information point
• Provisions for disconnection of power supply to the charging stations are included in the instal-
lation. If the electric vehicle is being charged, the charging infrastructure must be disconnected from the power supply before starting firefighting against a fire. Information on any necessary deactivation of the high-voltage parts of the vehicle is also publicly available on the National Highway Traffic Safety Administration website.
Additional measures for indoor charging locations in commercial occupancies:
• Even if “open” to the exterior, parking garages should be equipped with an automatic sprinkler system. Currently adopted codes specify minimum sprinkler system criteria of Ordinary Hazard Group 2. Regardless of the presence of batteries, the fire protection industry has questioned whether this design is sufficient to mitigate modern vehicle hazards. Vehicles today contain more combustible material and are larger. Currently, testing is being conducted to determine the appropriate level of sprinkler protection by the NFPA’s Fire Protection Research Foundation. Upon completion of this fire testing, code and regulations, such as NFPA 88A: Standard for Parking Structures, may adopt different sprinkler criteria. Insurance providers (Factory Mutal Data Sheet 03-26) currently recommend a sprinkler system that aligns with Extra Hazard Group 1 Occupancies. When installing a new EV charging station in a parking garage, stakeholders should consult subject matter experts to conduct a risk assessment to determine appropriate protection, considering the exposures and preventive/mitigative measures reasonably available.
• As an engineering best practice, an air aspirated smoke detection system or heat detection can be added to the existing fire alarm system to serve the areas where EVs charging stations are located to provide an early alarm of a fire event. This may allow for expedited fire department response, as well as providing more time for occupants to exit the structure.
• Ensure mechanical exhaust systems, if installed, within the parking garages are maintained and routinely tested in accordance with International Mechanical Code (IMC) and NFPA 92: Standard for Smoke Control Systems or the locally applicable mechanical code requirements for the occupancy.
• Maintain fire protection and life safety systems in accordance with relevant standards such as NFPA 75: Standard for the Fire Protection of Information Technology Equipment, NFPA 72: National Fire Alarm and Signaling Code, NFPA 80: Standard for Fire Doors and Other Opening Protectives and in accordance with manufacturer’s recommendations. As an example, ensure passive fire resistive assemblies such as rated walls and associated door opening systems are maintained and functional, as well as ensuring fire/ smoke door assemblies are not propped open within the parking garage.
There is no limit to where owners can charge an EV nowadays, as charging stations are becoming increasingly prevalent. There are inherent hazards in the charging process. To address those hazards, we recommend:
• Conduct engineering evaluation to establish which protective measures reduce risk for any given project.
• Understand feasible preventive measures.
• Specify listed/labeled equipment. While using low-quality options may look appealing due to lower upfront costs, they may lead to much higher costs in the likelier event of failure.
• Understand guidance is unclear on sprinkler design criteria for EV hazards and this is one mitigation measure to be weighed against other prevention/mitigation techniques used for any given installation. cse
Christopher Unangst, PE, CSP, PMP, is a Director of Engineering at Jensen Hughes. He is a principal on technical committee NFPA 800: Battery Safety Code. He is a 2026 40 Under 40 winner.
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ENGINEERING INSIGHTS
Designing data centers for rapid growth and modularity
Engineers discuss how rapid growth in AI-driven workloads is reshaping data center design and driving higher power densities.
CSE: What are some current trends in data centers?
Brook Gummere: There is growing conversation, though not yet a broad shift, about some organizations reconsidering on-premises data centers or expanding to hybrid environments. Increasing concerns around intellectual property protection when data is stored off-site are driving part of this dialogue.
Advances in server hardware and chip technologies are also enabling companies to create their own language models without sending sensitive datasets off-site. This gives some businesses more confidence in keeping proprietary data fully under their control. While a widespread move to in-house data centers has not yet materialized, data sovereignty requirements continue to expand. Regulations such as the U.S. CLOUD Act and various country-specific data residency laws are making cross-border data transfers more complex.
Objectives
• Understand how AI workloads are transforming infrastructure requirements and pushing the limits of traditional cooling and electrical systems.
• Evaluate emerging cooling and power strategies including the shift from air- to liquid-cooled systems.
• Assess the role of modularization and offsite construction using prefabricated systems and skid-mounted equipment to improve construction speed.
Anvay Joshi: A major trend in data centers is the rapid increase in rack densities and cooling splits, especially when artificial intelligence (AI) workloads are involved. A couple of years ago, I worked on a hyperscale project that was predominantly air-cooled. Projects today are moving toward up to 80% liquid and 20% air-cooled splits. Additionally, the load profiles of AI data centers usually show sudden ramp-ups and ramp-downs, which call for the use of buffers in cooling systems. Because the cooling equipment cannot ramp up or down at the same rate, thermal energy storage (TES) or large buffer tanks are becoming more common.
On the electrical side, there is increasing state-level conversation around on-site generation, battery storage and renewable energy procurement for data centers. For sites with space restrictions and those located in denser neighborhoods, cooling equipment is being placed on dunnage platforms with canopies to avoid hot air reentrainment. Additionally, a greater focus is placed on sound mitigation options from equipment manufacturers to ensure compliance with local laws.
Bill Kosik: Over the past 12 months, there has been a sea change in the data center design and construction industry. After a few years of straightforward power and cooling system design, AI clusters have completely rewritten the rules for data centers. The relatively high power densities of the AI power stack will approach a 10-time increase in power and
cooling. These challenges are technically feasible to be solved, but there are not many examples to draw on as a starting point.
Kenneth Kutsmeda: Grid constraints are pushing new data center campuses into remote geographies where land is available for on-site generation and where limited grid capacity still exists. These locations often lack the skilled labor force needed for traditional, labor-intensive construction methods.
To address this, developers are adopting skid-mounted, modular or premanufactured systems that can be assembled, integrated and tested off-site. This approach offers several advantages including reduced on-site labor requirements, shorter construction schedules, higher quality control and parallelization of work, which allows mechanical and electrical systems to be built before the data hall structure is complete.
Daniel Noto: In the data center industry, the key is planning, whether that means leaving room for additional racks and expansion or planning for what information can go to the cloud or even using colocation strategies. Regardless, it’s planning for increased needs for data storage that is driving data center conversations today.
Ken Urbanek: The elephant in the room is AI and this trend is driving heavy energy use and new techniques for mechanical, electrical and plumbing (MEP) system design.
Participants
Brook Gummere, PE, FPE, ATD
Colorado BES Market
Sector Leader
HDR
Denver
Anvay Joshi, PE
Mechanical Engineer II Affiliated Engineers Inc. Madison, Wisconsin
CSE: Within the next three years, what trends should engineers or designers expect for such projects?
Bill Kosik: Current AI cabinet power density is still ramping up. Manufacturers of graphics processing units (GPUs) and tensor processing units (TPUs) have published cabinet densities in the 300-kilowatt (kW) range. But with current AI cabinet densities in the 150-kW range, a more practical three-year forecast for AI systems is 120 to 300 kW, with maximum AI cabinet densities of 300 to 400 kW.
Anvay Joshi: The recent growth of AI workload needs has resulted in a push to build data centers at a faster rate than previously seen. With speed to market at the forefront, packaged skids are already becoming products that engineers are turning to. Pushing the assembly of equipment off-site improves installation and setup time. Coolant distribution units (CDUs), which are essentially pumps, heat exchangers and other auxiliary equipment skidded into a single packaged unit
are a good example of this trend. CDUs are already ubiquitous in the data center industry.
As site procurement becomes expensive and air-cooled data centers age, there will be massive interest in retrofit projects for existing data centers going through equipment replacements. Lastly, with power availability becoming a major constraint, phased data center projects will be more common as owners work to procure the power required for their sites.
Brook Gummere: Over the next one to three years, engineers can expect data center projects to focus on sharply rising rack-level power demands driven by next-generation AI hardware such as specialized GPUs that deliver significantly higher performance per watt and require greater electrical and cooling capacity. Likewise, the growing adoption of TPUs also will lead to larger campuses on gigawatt scales. To support large-scale AI training, tightly clustered GPUs will become essential to reduce latency between computing elements.
Bill Kosik, PE, CEM, LEED AP
Mission Critical Sector Leader
Chicago
Kenneth Kutsmeda, PE, LEED AP
Global Technology Leader – Data Centers
Jacobs
Philadelphia
Daniel Noto, PE, LEED AP
Southeast Market Leader
Fitzemeyer & Tocci Associates Inc.
Alpharetta, Georgia
Brian Schlosser, PE Principal Fire Protection Engineer
Jensen Hughes Columbia, Maryland
Ken Urbanek, PE, LEED AP, ASHRAE HBDP, ATD
Client Executive and Senior Principal IMEG
Denver
Kenneth Kutsmeda: Power densities in AI data centers are accelerating far beyond the historical 20% generation-
FIGURE 1: St. Joseph’s Hospital, Nashua, New Hampshire. Courtesy: Fitzemeyer & Tocci Associates Inc.
ENGINEERING INSIGHTS
over-generation growth rate, creating requirements that exceed the practical limits of traditional alternating current (AC) distribution. To support these unprecedented densities, high-voltage direct current (DC) architectures are being evaluated, drawing on established practices from the electric vehicle, photovoltaic and traction power industries, where high-voltage DC is already mature and widely deployed.
Adopting 750 or 800 volts (V) DC provides several technical advantages over conventional 480 VAC systems. This includes: elimination of multiple conversion stages between AC to DC and DC to AC, improving overall system efficiency; lower distribution losses due to reduced current for the same power level; significant reduction in copper cabling and associated thermal management requirements; and direct compatibility with energy storage systems, which inherently operate on
DC and can be integrated without additional conversion hardware.
Ken Urbanek: Proximity and system density are critical to optimizing AI computations. As a result, rack densities will continue pushing the limits of power and cooling requirements at the rack level.
CSE: How is the rapid growth of AI workloads and high-density computing changing cooling, power distribution and mechanical/electrical design strategies in data centers?
Daniel Noto: AI training/inference clusters are pushing rack power densities from “typical enterprise” levels of approximately 5 to 15 kW per rack into 30 to 60 kW per rack and, for leading GPU racks, toward roughly 100 kW per rack and higher. Once you’re in that range, air cannot move heat fast enough (or efficiently) without extreme airflow, noise and fan
power — so data center design is shifting from room-level air cooling and standard electrical rooms to chip-to-facility thermal and electrical engineering.
Ken Urbanek: Rack densities have gone from 10, 20 and 30 kW per rack being considered high density a few years ago to regular AI deployments going well beyond 100 kW per rack and in many cases two to five times higher than this.
Brian Schlosser: The code development process takes time and often lags the need for developing, for example, fire protection schemes for new mechanical and electrical technologies associated with data centers. Historical examples include development of hot/cold aisle containment systems and the use of lithium-ion batteries. Building information modeling has proven to be extremely effective in coordinating and collaborating among various design disciplines to reduce clashes between building systems.
Continued on pg. 46
2: Concept schematic for converting a district chilled water system to ambient loop for highperformance computing data center heat recovery. Courtesy: IMEG
FIGURE
ENGINEERING INSIGHTS
Continued from pg. 44
Anvay Joshi: Cooling systems in data centers are shifting from traditional room-level air cooling to more localized solutions, such as direct-to-chip liquid cooling. For example, the recently announced NVIDIA Vera Rubin can handle inlet water temperatures up to 113°F. The acceptable server inlet water temperatures have increased over the years, allowing for more efficient cooling strategies.
(CPUs), which execute instructions in a largely linear fashion. CPU-based workloads are typically asynchronous and uncorrelated, causing individual servers to draw power at different times. This diversity smooths the aggregate load profile and produces relatively stable power demand across the facility.
AI-focused data centers, by contrast, are built around GPUs designed for massively parallel computation. GPU work-
‘As rack densities increase, a project could encounter space constraints for mechanical equipment.’
On the power distribution side, greater density calls for larger busways or power distribution units. Coordination between mechanical and electrical disciplines is critical at an early stage to define redundancy requirements for equipment.
Bill Kosik: If we look back 10 years on the forecasted versus actual server cabinet power demand, there was concern on how to provide power and cooling to “high-density” cabinets. At that time, the forecast for server cabinet power ranged from 10 to 20 kW. Based on these forecasts, the data center engineering community, along with power and cooling equipment manufacturers, developed new approaches to tackle this problem.
From these efforts, two lessons emerged: First, few colocation and enterprise data centers ever got to these densities, but if they did, it was for specialized computing needs and not widespread across the data halls. This led to stranded power and cooling infrastructure due to overestimating power densities. (It must be noted that cabinet power density for high-performance and supercomputing applications at this time ranged from 50 to over 100 kW.) Second, the AI cabinet power densities are growing at a far higher rate than what we saw in the past.
Kenneth Kutsmeda: Traditional data centers rely on central processing units
loads operate synchronously, with large clusters executing identical operations on shared datasets. This synchronization creates highly correlated power patterns, resulting in rapid transitions between low- and peak-load states. In addition, GPU cabinets exhibit significantly higher power densities, commonly 60 to 200 kW per rack, far exceeding traditional CPU deployments.
CSE: What are the biggest challenges around utility coordination, power availability and grid interconnection for new data center developments?
Ken Urbanek: The biggest challenge is finding suitable data center locations that can either provide power on a reasonable timeframe or that have space to deploy on-site power generation such as fuel cells.
Bill Kosik: As data center developers and owners requested generation capacity and transmission for AI data centers, the legacy process that utilities used to enter into an agreement with the data center no longer worked for AI facilities, which put the spotlight on the utilities and grid operators. For the first time, the Federal Energy Regulatory Commission became involved in the oversight of current methods and mandated that new processes and proto-
cols be implemented to ensure electricity requests were executed fairly, at a reasonable cost and safely.
These processes were put in place in late 2025. It appears that using this process is improving the method for estimating data center load and includes penalties for data center operators that do not achieve the agreed-upon minimum power estimates.
Kenneth Kutsmeda: The primary constraint is the limited available capacity on the utility grid. Data center load growth is outpacing the timelines for transmission and distribution system expansion, creating persistent deficits in deliverable power. As a result, developers can no longer rely on the utility as a single, firm source of supply. Many facilities are shifting to hybrid power architectures that integrate utility service with on-site generation, temporary feeders or mobile substation assets.
As these hybrid strategies proliferate, microgrid control becomes critical. Coordinating multiple sources requires precise management of interconnection points, relay protection schemes, anti-backfeed measures and load-demand response. Effective control is essential to maintain high power availability, ensure stable transitions between sources and protect both the data center infrastructure and the utility network.
CSE: How is the growth of cloudbased storage and virtualization impacting colocation projects?
Daniel Noto: Demand is shifting from many small single-tenant deployments to fewer, larger, high-density and highly flexible environments designed for cloud providers and hybrid information technology (IT). Instead of traditional cabinets with predictable loads, colocation facilities now need scalable power blocks, higher rack densities and network-rich interconnection to support hyperscale and multi-cloud ecosystems. Virtualization allows customers to run far more workloads on fewer physical serv-
ers, which reduces the number of racks per tenant but increases power density, bandwidth demand and resilience expectations, pushing operators to design facilities with modular expansion, software-defined infrastructure compatibility and stronger connectivity to public cloud on-ramps. As a result, modern colocation developments emphasize carrier neutrality, rapid deployment suites, flexible lease structures and robust power/cooling infrastructure to attract enterprises adopting hybrid and multi-cloud strategies.
Ken Urbanek: This continues to be an area of growth as exponentially more data is generated each day.
CSE: Tell us about a recent project you’ve worked on that is innovative, large-scale or otherwise noteworthy.
Anvay Joshi: For a recent large-scale project, we used a hybrid dry cooler and air-cooled chiller (ACC) plant design with TES tanks. The CDUs would be served primarily by dry coolers, but on peak days, the TES tanks provide blended chilled water with the dry coolers. The ACC plant serves the air side load and charges the TES tanks during off-peak hours, improving plant flexibility. A challenge for the site was the limited space available for equipment placement. We had to conduct extensive CFD analysis to validate the spacing between ACCs and dry coolers to ensure reentrainment was kept at a minimum. Thorough coordination between different disciplines was necessary to iterate the design from mechanical, structural, electrical and civil perspectives.
Brook Gummere: Recently, we have been leading the design of several large-scale data centers in rural communities where existing infrastructure cannot support the increased utility demands. These projects have required collaborative partnerships with local governments and utilities to upgrade existing water, wastewater, power, fiber and roadway systems. A key challenge and opportunity has been looking beyond the data center to understand what the surrounding community needs to sustain both construction and long-term operations.
Our teams have helped clients develop training programs with trade schools and community colleges, building excitement about careers in mission-critical infrastructure with students. Additionally, we are increasingly exploring locations with direct access to renewable energy generation such as offshore wind paired with energy storage systems to reduce dependence on constrained transmission networks and also to accelerate project delivery.
Ken Urbanek: One recent example is an AI high-performance computing (HPC) center we are deploying on a northern latitude university campus. We can extract the low-grade heat from the computing operations and push it into the campus district energy system. This HPC is relatively small, only 15 megawatts, but it has the potential to be an energy source for heat pump heating of
millions of square feet of campus classroom space. Deploying this requires communication between HPC operators, broader campus facilities and alignment with the campus decarbonization plan.
This is a great example of coupling these data centers with adjacent uses that can use waste heat. This can be especially beneficial if the adjacent uses such as health care or higher education campuses are looking for electrification opportunities to decarbonize their campuses. This synergistic relationship is much preferred over throwing waste heat into the atmosphere, which sadly is all too common in data centers across the U.S. We are seeing data centers outside the U.S. consider other unique uses such as heating greenhouses and even heating a trout farm. cse
Insights
csemag.com
Data center insights
uArtificial intelligence is forcing a fundamental redesign of data center infrastructure due to explosive increases in rack power density and synchronized graphics processing unit workloads.
uSpeed, scalability and power constraints are accelerating modular and hybrid solutions such as prefabricated systems, on-site generation and phased buildouts to overcome grid limitations and aggressive timelines.
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