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Originally under the Energy Efficient Industrialized Housing
Program (EEIH0 and now under BAIHP, FSEC collaborates with
Palm Harbor Homes (PHH) offering building science advice and
conducting diagnostic testing which includes infrared camera
inspection. As a result, PHH now incorporates added return
air transfer ducts to minimize pressure imbalances in the
conditioned space. The company also tests duct leakage on
every home in every factory with ductblaster equipment.
Presently, all PHH factories are in the process of certification
under the new Energy Star guidelines for manufactured homes.
Six plant certifications were completed by August 2003, with
four additional plants scheduled for certification. (Please
see Figure 9.)
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| 5Figure 9. A Palm Harbor
Energy Star home manufactured in Plant City, Florida. |
National
Outreach:
$ Energy Gauge: Staff conducted several Energy Gauge ratings and code compliance
analyses for PHH Plant City and performed two additional PHH
simulation comparisons of standard HUD versus upgraded homes
for Detroit, Michigan, Morgantown, West Virginia and Missoula,
Montana plants.
$ EnerGMiser Energy
Management System: Researchers conducted an analysis
of the PHH EnerGMiser Energy Management System and quantified
the energy savings over base-case HUD code homes in 40+ US
cities. Energy savings ranged from 28% to 42%. The results
of these analyses are listed at the PHH corporate web site
at www.palmharbor.com/our_homes/home_features/energy_management_system.
Albemarle,
North Carolina: FSEC
contacted the North Carolina engineering manager for information
on Palm Harbor's typical model construction specifications
in order to begin Energy Star qualifying procedures. Two
PHH model analyses for three different climate zones were
run to assess initial energy efficiency. These tests were
rerun once specific window SHGCs were received from PHH.
February 24 and 25, 2003, FSEC conducted a plant visit to
direct and oversee Energy Star certification tests on six
floor models. Tests were completed by FSEC and by factory
personnel with FSEC oversight. All models passed the 3% leakage
limit. To complete the certification, three additional site
installed homes will be tested for compliance.
FSEC staff also worked with the plant engineer on builder
option packages (BOPs) versus software options as a means
to qualify homes for Energy Star. It was determined that
qualifying homes in Energy Star zones 3 and 4 will be feasible
using BOPs, but EGUSA will be needed to certify at least some
of the zone 2 homes.
Austin,
Texas: PHH initiated certification procedures for Energy Star per
the EPA/MHRA guidelines. Staff completed the reporting and
certification on two PHH Austin homes in the Houston area
for Energy Star compliance. One home passed and the other
failed due to belly board installation problems. (Please
see Figures 10 and 11.) These belly board problems have since
been addressed and the Austin plant and the remaining three
Texas plants are currently being certified for Energy Star
production.
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Figure 10. Another belly
tear found during
inspection. |
Figure 11. Worst belly tear
near plumbing penetration. |
Plant
City, Florida:
$ Energy Star: Researchers initiated certification
procedures for Energy Star per the EPA/MHRA guidelines. FSEC
reviewed the Design Approval Inspection Agency (DAPIA) packages
and design procedures. The PHH Plant City factory was certified
in February 2003 and registered one Energy Star home in Polk
County, Florida.
FSEC met with the plant engineer on September 16 and 17,
2002 to analyze several new models for Energy Star eligibility.
The analysis was conducted using EGUSA software (v-1.32).
Researchers assisted the plant engineer with a combination
of EGUSA software and BOPs, so that all plant models over
several states could reach Energy Star levels.
$ Insider Heat Pumps: In 2001, five model
homes at PHH-Plant City were tested for return air performance.
Two of the homes were modular with Insider heat pumps. Performance
results and recommendations were submitted to the plant engineer.
Staff retested two modulars with Insider heat pumps and determined
that leakage in the condenser fan compartment was depressurizing
the homes. Further testing on other Insider installations
is needed to uncover the scope of this problem and plans are
in progress to find the best corrective course of action.
BAIHP will visit PHH Plant City and observe the installation
when the next Insider heat pump is requested. Researchers
will look for installation problem areas and perform additional
home tests.
$ Technical Assistance: Diagnostic tests were conducted
in 2002 on a home in Odessa, Florida manufactured by PHH-Plant
City. This visit was requested by PHH after they received
a homeowner high-utility bill complaint. Inspections with
the infrared (IR) camera found no insulation problems and
ductblaster and blower door tests revealed airtight duct and
envelope systems. Other than an oversized air conditioning
system, there were no obvious reasons for the high bills.
The homeowner was satisfied with the investigation and apologized
for their written complaint.
Sabina,
Georgia: PHH signed an Energy Star Partnership Agreement to begin certification
of the Sabina Plant. Two model home plans were analyzed,
each with a gas furnace and with a heat pump, using EnergyGauge
USA software. The plant certification visit and site-installed
home ratings were done in Spring 2002 and certification paperwork
was forwarded to the EPA for plant registration. PHH is
planning a 54-unit development in Wilmington, Ohio. Modifications
made at the Sabina Plant should be very helpful for the Wilmington
endeavor
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