C109584- Attachment A- Bridging Documents.pdf

Building 105 Standby Power for Chilled Water Generation 111 T.W. Alexander Drive Research Triangle Park, NC 27709

Bridging Documents

NIH WR NO: C109584

AEI NO: 22428-00

Issued: December 9th, 2022

Submitted by:

In Partnership with

Bennett & Pless The Timmons Group

NIH Edits for SOW: April 26th, 2024

National Institute of Environmental Health Sciences Durham, North Carolina Building 105 Standby Power for Chilled Water Generation Work Request No: C109584

AEI No: 22428-00 BASIS OF DESIGN

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TABLE OF CONTENTS

1. Statement of Work

2. Background

3. Project Objective

4. Backup Power Distribution System

5. Construction Phasing

6. Environmental

7. Civil & landscape

8. Structural

9. Mechanical HVAC

10. Mechanical Fuel Oil

11. Fire Suppression

12. Electrical

13. Plant Controls

14. Security

APPENDICES

A Drawings G001 Title Sheet

C101 Existing Conditions and Demo Plan C201 Site Plan C301 Grading and Erosion Control Plan C401 Details

SU101 Site Utility – Overall Site Plan

S001 General Notes S100 Foundation Plan

M001 Mechanical Symbols & Abbreviations M101 Enlarged Fuel Oil Site Plan M201 Mechanical Plan – North Electrical Room and Generator Yard M401 Fuel Oil System P&ID M601 Mechanical Schedules

E001 Electrical Symbols & Abbreviations E101 Enlarged Electrical Site Plan – Generator Yard E102 Enlarge Electrical Site Plan – Building 105 Service Entrance E103 Enlarged Electrical Plan – Walk-In Enclosures EP201 Power Plan – North Electrical Room and Generator Yard – Phase N1 EP202 Power Plan – North Electrical Room and Generator Yard – Phase N2 EP203 Power Plan – North Electrical Room and Generator Yard – Phase N3 EP204 Power Plan – North Electrical Room and Generator Yard – Phase N4

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EP205 Power Plan – North Electrical Room and Generator Yard – Phase N5 EP206 Power Plan – North Electrical Room and Generator Yard – Phase N6 EP211 Power Plan – South Electrical Room EL201 Lighting Plan – North Electrical Room and Generator Yard – Demo &

New Work ES201 Systems Plan – North Electrical Room and Generator Yard – Demo &

New Work E400 Medium Voltage Electrical Single Line Diagram – Phase S2 E401 Medium Voltage Electrical Single Line Diagram – Phase N1 E402 Medium Voltage Electrical Single Line Diagram – Phase N2 E403 Medium Voltage Electrical Single Line Diagram – Phase N3 E404 Medium Voltage Electrical Single Line Diagram – Phase N4 E411 North Plant 480V Electrical Single Line Diagram – Demo Work E412 North Plant 480V Electrical Single Line Diagram – New Work E421 Auxiliary Generator and Control Power Single Line Diagram E431 Grounding Riser Diagram E501 Electrical Details E601 Electrical Panel Schedules E701 Detailed Single Line Diagram and Elevation – ESGCP1 E702 Detailed Single Line Diagram and Elevation – ESGCP2 E703 Detailed Single Line Diagram and Elevation – SGCP2 E704 Detailed Single Line Diagram and Elevation – Substation A/B E801 Electrical Power Monitoring and Control Systems Interconnection

Diagram

B Specifications 26 0913 Electrical Power Monitoring and Control System (EPCS) 26 0914 Supervisory Control and Data Acquisition (SCADA) 26 1113 Primary Unit Substations 26 1216 Dry-Type, Medium-Voltage Transformers 26 1219 Deadfront Pad Mount Transformers 26 1319.1 Medium-Voltage Switchgear Package 26 1319.2 Medium-Voltage Generator Paralleling Switchgear 26 1319.3 Medium-Voltage Non-Generator Switchgear 26 1319.4 DC Battery System 26 2301 Walk-In Enclosure 26 3213 Medium-Voltage Engine Generator Sets 26 3214 Medium-Voltage Load Bank

C Geotechnical Exploration Report

D Generator Vendor Calculation

E C109584 Building 105 Emergency Chilled Water Generation Final Report

F B105 North and South Electrical Rooms As-Built Documentation G001 Title Sheet G201 Overall Floor Plans G301 North Electrical Room Sections G302 North Electrical Room Sections G303 Generator Yard Sections

Not Used grotheerdg Cross-Out

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G304 South Electrical Room Sections G305 South Electrical Room Sections G306 South Electrical Room Sections G311 N. Elec. Room Gen Yard – Isometric Views G312 N. Elec. Room Gen Yard – Isometric Views A201 Floor Plan – First Floor A202 Roof Plan A301 Enlarged Floor Plan S201 Slab Plan S202 Roof Framing Plan M201 Mechanical Plan M601 Mechanical Schedules E001 Symbols, Notes and Abbreviations E101 Electrical Overall Floor Plan EL201 Lighting Plan – North Electrical Room and Generator Yard EL202 Lighting Plan – South Electrical Room EP201 Power Plan – North Electrical Room and Generator Yard EP202 Power Plan – South Electrical Room FA201 Fire Alarm Plan – North Electrical Room and Generator Yard FA202 Fire Alarm Plan – South Electrical Room E401 Medium Voltage Electrical Single Line Diagram E411 North Plant 480V Electrical Single Line Diagram E412 South Plant 480V Electrical Single Line Diagram

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1. STATEMENT OF WORK

The NIH Building 105 Standby Power for Chilled Water Generation project is to provide a backup 13.8kV power distribution system to support chilled water distribution to the NIEHS portion of campus. The requirement identified by NIH for standby power for chilled water is the capability to start and run one 3500-ton VFD driven chiller within the North Plant and its associated pumps and cooling towers to serve the NIEHS campus chilled water load for a minimum of 72 hours. The backup power distribution shall be expandable and modify the existing normal power 13.8kV distribution for buildings 102, and 104 in addition to building 105.

New 13.8kV generators, switchgear and controls enclosures shall be oriented in a new equipment yard located in an undeveloped area south of Building 105. Medium voltage and controls ductbanks shall be routed to existing manholes for connectivity. Electrical equipment;

including but not limited to, 13.8kV switchgear, 4.16kV substation, 480V generator and 480V distribution equipment, within the North Electrical Room of building 105 shall be demolished and replaced in a phased manner with minimal disruption to Building 106 and Building 108.

The project scope of work shall include, but not be limited to, the following:

• Installation of new site utilities for the equipment yard including electrical ductbank, telecommunications ductbank, storm sewer and re-routing reclaim water.

• Installation of new medium voltage conductors from Building 107 to new equipment yard and from equipment yard to support Buildings 102, 104 Computer Room, 105, and site transformers

• Excavation, retaining walls, fencing, paving, grading, erosion control and storm water management of the proposed construction site.

• Foundations, walls, floors and structural assemblies for the 13.8kV cable vault within the equipment yard.

• Equipment pads and steps for access to walk-in enclosures.

• Electrical systems including 13.8kV generators, switchgears, 4.16kV substation and low voltage distribution equipment

• Electrical control systems for the backup power distribution system and integration into existing plant SCADA and existing electrical distribution SCADA.

• Equipment walk-in enclosures for the 13.8kV switchgears, controls equipment and generators within the equipment yard.

• Mechanical fuel oil systems, piping, valves and controls to extend the existing fuel oil system to the generators within the equipment yard.

• Mechanical systems, ductwork, piping, insulation, and controls to modify the Building 105 North Electrical Room HVAC.

• Security systems for equipment yard including card access and physical measures.

• Start-up, testing and balancing, and assistance to commissioning agents for the equipment, mechanical and electrical systems provided by the project to verify the operation, integration, and functionality of the new electrical and mechanical systems and impact on existing Building 105 plant control systems.

The prospective design-build contractor shall be responsible to develop the bridging documents presented to 100% construction documents. This documentation shall include, but not be limited to, the following:

• Compliance with NIH Design Requirements Manual (DRM) and Engineering Standards and Material Requirements (ESMR)

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• Environmental studies per the DRM inclusive of at a minimum the following; exhaust entrainment study, vibration study, noise study, air permit study.

• Project Schedule

• Project cost to design, construct and maintain.

• Project Drawings for Civil, Structural, Architectural, Mechanical, Electrical, Fire Alarm and Security scope

• Project Specifications to include at a minimum the following sections:

DIVISION 00 – PROCUREMENT AND CONTRACTING REQUIREMENTS

00 0101 Project Title Page 00 0107 Seals Page 00 0110 Table of Contents

DIVISION 01 – GENERAL REQUIREMENTS

01 0000 General Provisions 01 0010 Summary of Work 01 0011 Alternates 01 0012 Unit Prices 01 0040 Work Restrictions 01 0045 Cutting and Patching 01 0290 Payment Procedures 01 0310 Project Management and Coordination 01 0316 Scheduling Requirements 01 0320 Construction Progress/Photographic Documentation 01 0330 Submittals 01 0410 Regulatory Requirements 01 0500 Temporary Facilities and Controls 01 0502 Tree Protection 01 0505 Construction Waste Management and Disposal 01 0510 Temporary Utilities 01 0520 Construction Facilities 01 0525 Maintenance of Traffic and Parking 01 0550 Vehicular Access and Parking 01 0560 Temporary Barriers and Enclosures 01 0580 Project Identification and Signs 01 0690 Field Engineering 01 3523 Use, Handling, Storage, Transporting and Disposal of NIH Controlled

Material 013526 Safety and Health Activity Hazard Analysis Form (AHA) Affirmation of NIH Contractor Safety Deliverables 01 3526.23 NIH Fire Prevention Precautions for Hot Work 01 4500 NIH Construction Quality Control 01 7700 Contract Closeout 01 7839 Project Record Documents & Contractor As-Builts 01 7823 Operations and Maintenance Data 01 7900 Demonstration and Training 01 9100 General Commissioning Requirements 01 9110 Functional Performance Testing Procedures grotheerdg Cross-Out grotheerdg Cross-Out

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DIVISION 02 – EXISTING CONDITIONS

024119 Selective Demolition

DIVISION 03 – CONCRETE

03 3000 Cast-In-Place Concrete

DIVISION 08 – DOORS AND WINDOWS

08 1113 Hollow Metal Doors and Frames

DIVISION 10 – SPECIALTIES

10 4400 Fire Extinguishers & Cabinets and Accessories

DIVISION 22 – PIPING

22 0000 General Plumbing Requirements 22 0215 Excavation and Backfill 22 0529 Piping and Equipment Supporting Devices 22 0553 Plumbing Systems Identification 22 0573 Plumbing Systems Firestopping 22 0594 Water Systems Test and Balance 22 0700 Plumbing Systems Insulation 22 1100 Water Distribution System 22 1300 Sanitary Waste and Storm Drainage System 22 2114 Plumbing Specialties 22 3314 Water Heating Equipment 22 4000 Plumbing Fixtures

DIVISION 23 – MECHANICAL

23 0000 General Mechanical Requirements 23 0513 Motors 23 0515 Variable Frequency Drive (VFD) System 23 0529 Mechanical Supporting Devices 23 0553 Mechanical Systems Identification 23 0594 Water Systems Test Adjust Balance 23 0595 Air Systems Test Adjust Balance 23 1214 Liquid Fuel Systems 23 2114 Underground (Direct Buried) Piping 23 2116 Pipe and Pipe Fittings 23 2118 Valves 23 2420 Pumps 23 3114 Ductwork 23 3314 Ductwork Specialties 23 3400 Fans 23 3713 Diffusers, Registers and Grilles 23 7313 Packaged Air Handling Units

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DIVISION 25 – INTEGRATED AUTOMATION

25 0553 Instrumentation Tagging 25 0800 Process Control System Commissioning 25 0900 Control Integration & Project Management 25 0901 Control Integration 25 0902 Control Valves and Dampers 25 0903 Controls Instrumentation 25 0993 Control Sequences 25 1005 Industrial Ethernet 25 1100 Programmable Process Controllers 25 1316 Control Panels 25 1326 Control Panels Factory Acceptance Test (FAT) 25 1514 Process Control Application Software Design 25 1522 Graphical User Interface Hardware & System Software 25 1524 Graphical User Interface Application Design 25 3001 General Instrumentation Requirements 25 3003 Process Control Instrumentation 25 5010 Data Historian Integration and Measurement and Verification 25 6010 Field Instrument Loop Check

DIVISION 26 – ELECTRICAL

26 0000 General Electrical Requirements 26 0191 Electrical Systems Commissioning Requirements 26 0513.16 Medium-Voltage Single and Multi-Conductor Cables 26 0519 Low-Voltage Electrical Power Conductors and Cables 26 0526 Grounding and Bonding for Electrical Systems 26 0529 Hangers and Supports for Electrical Systems 26 0533 Raceway and Boxes for Electrical Systems 26 0536 Cable Trays for Electrical Systems 26 0543 Underground Ducts and Raceways for Electrical Systems 26 0543.13 Excavation and Backfill 26 0543.19 Manholes and Handholes 26 0553 Electrical Systems Identification 26 0573 Power System Studies 26 0812 Power Distribution Acceptance Tests 26 0813 Power Distribution Acceptance Test Tables 26 0913 Electrical Power Monitoring and Control System (EPCS) 26 0914 Supervisory Control and Data Acquisition (SCADA) 26 1113 Primary Unit Substations 26 1216 Dry-Type, Medium-Voltage Transformers 26 1219 Deadfront Pad-Mount Transformers 26 1319.1 Medium-Voltage Switchgear Package 26 1319.2 Medium-Voltage Generator Paralleling Switchgear 26 1319.3 Medium-Voltage Non-Generator Switchgear 26 1319.4 DC Battery System 26 2200 Low-Voltage Transformers 26 2300 Low-Voltage Switchgear 26 2301 Walk-in Enclosure 26 2413 Switchboards

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26 2416.13 Lighting and Appliance Panelboards 26 2416.16 Distribution Panelboards 26 2713 Electrical Metering 26 2726 Wiring Devices 26 2816 Enclosed Switches and Circuit Breakers 26 2913 Enclosed Controllers 26 3213 Medium-Voltage Engine Generator Sets 26 3214 Medium-Voltage Load Bank 26 4113 Lightning Protection for Structures 26 4300 Surge Protective Devices 26 5000 Lighting

DIVISION 27 – COMMUNICATIONS

27 0000 General Communications Requirements 27 0526 Grounding and Bonding for Communications 27 0528.29 Hangers and Supports for Communications 27 0528.33 Raceways and Boxes for Communications 27 0528.36 Cable Trays for Communications Systems 27 0553 Communications Systems Identification 27 1000 Structured Cabling 27 1100 Communications Equipment 27 1300 Communications Cabling 27 1500 Communications Horizontal Cabling 27 1600 Communications Connecting Cords, Devices and Adapters

DIVISION 28 –ELECTRONIC SAFETY AND SECURITY

28 1000 Electronic Safety and Security 28 3113 Multiplexed Fire Alarm Detection System

DIVISION 31 – EARTHWORK

31 1000 Site Clearing and Grubbing 31 2000 Earth Moving 31 2500 Erosion and Sediment Controls 31 3116 Termite Control 31 2316 General Excavation 31 2320 Unclassified Excavation for Utilities 31 2322 Trenching, Bedding and Backfilling for Waterlines and Sewage

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DIVISION 32 – EXTERIOR IMPROVEMENTS

32 1216 Asphalt Paving 32 1313 Concrete Paving 32 1700 Pavement Markings, Signs and Specialties 32 3113 Fences and Gates 32 9200 Lawns and Grasses 32 9300 Exterior Plants

DIVISION 33 – UTILITIES

33 1000 Water Drainage Utilities 33 4000 Storm Sewer Utilities

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2. BACKGROUND

The Central Utility Plant (CUP) at Building 105 produces Chilled Water (CHW) and High Temperature Hot Water (HTHW) for the entire NIEHS/EPA campus in the Research Triangle Park, NC, including vivariums and research laboratories. The CUP is fed electrically by multiple 13.8kV feeders from the main campus 112.5kV/13.8kV substation in Building 107. The CUP is divided into a North and South Plant. Refer to Figure 1 for existing site plan. Each plant can operate independently to provide CHW and HTHW to the campus. The electrical equipment associate with each plant is primarily located within an electrical room for each respective plant or out on the Chiller Plant and Boiler Plant floor.

The North Plant houses 4160V chillers 2 & 3 and associated pumps and cooling towers. The North plant also includes 480V HTHW Generators 2 & 3 and associated HTHW pumps.

The South Plant houses 4160V chillers 4, 5 & 6 and associated pumps and cooling towers. The South plant also includes 480V HTHW generators 4 & 5 and associated HTHW pumps.

Each plant has a dedicated 480V generator capable of serving each plant’s respective HTHW plants, as well as the CUP’s control systems and emergency loads. Each generator has a diesel fuel day tank that is piped to the main diesel fuel oil tanks outside the Boiler Plant. The existing generators are located in an open-air area between the electrical rooms for the North and South Plants.

Refer to Figure 2 for a simplified single line diagram of the existing electrical distribution system for the North and South Plants.

The current configuration of the 480V diesel generators cannot start or run the 4160V chillers.

Without utility power available, the CUP cannot provide chilled water to buildings on campus.

Figure 1 – Aerial View of CUP and B107 Substation

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Figure 2 – Existing Simplified Single Line Diagram

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3. PROJECT OBJECTIVE

The project objective is to provide a backup power distribution system to support chilled water distribution to the NIEHS portion of campus. The requirement identified by NIH for standby power for chilled water is the capability to start and run one 3500-ton VFD driven chiller within the North Plant and its associated pumps and cooling towers to serve the NIEHS campus chilled water load. The backup power distribution must be capable to expand in the future to support starting and running two 3500-ton chillers. The backup power distribution system must be capable of running the chiller, or chillers in the future, and all related controls, cabinets, and air compressors for a minimum of 72 hours to account for a prolonged utility outage and align with individual building generators located at other buildings on campus.

In addition to the backup power distribution system, there is various electrical equipment associated with the North Plant that has or is reaching the end of its service life and replacement components are no longer available. That equipment must be replaced in conjunction with the new backup power distribution equipment. The following North Plant electrical equipment has been identified by NIH to be replaced:

• 13.8kV Siemens-Allis Switchgear

• Substation A/B Transformers and Switchgear serving Chiller 2

• Substation F/G Transformers and Switchgear serving Chiller 3

• 480V Network Transformers T-C, and T-E

• 480V 1000kW Generator

• 480V Distribution Panel PP-P5

• 480V Distribution Panel PP-P6

• Existing Batteries and Battery Controller

Additionally, the following equipment has been identified for demolition without replacement

• 480V Network Transformer T-D

• 480V Automatic Transfer Switches ATS-2, ATS-3, and ATS-5

• 480V Generator distribution panel PP-P6

• 480V Russelectric Generator Control Panel

The installation of backup power distribution and electrical equipment replacement must be phased in a manner to maintain chilled water and hot water production to campus.

The design build contractor shall comply with the requirements of the current NIH Design Requirement Manual (DRM) for building information modeling of architectural, structural, civil and MEP systems. The DRM is available on the NIH website at the following link:

https://orf.od.nih.gov/TechnicalResources/Pages/DesignRequirementsManual2016.aspx. This shall include utilizing the latest version of Autodesk Revit.

https://orf.od.nih.gov/TechnicalResources/Pages/DesignRequirementsManual2016.aspx

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4. BACKUP POWER DISTRIBUTION SYSTEM

A study was performed in 2022 to evaluate different configurations and equipment locations for the Backup Power Distribution System. The recommendation of this study was to provide a 13.8kV diesel generator system primarily located south of B105. Refer to Figure 3 for the equipment yard location. Refer to Figure 4 for the proposed simplified single line diagram.

Figure 3 - Aerial View of Site with New Equipment Yard

The recommended solution shall provide two new 13.8kV switchgears, each in an outdoor walk-in enclosure. These switchgears are arranged to effectively operate as a single switchgear, fed from four separate 13.8kV feeders from the B107 substation and backed up by two 2000kW diesel generators operating in parallel, expandable to four generators in the future. The outdoor switchgears re-feed the existing 13.8kV switchgear for the South Plant and feed a new 13.8kV switchgear for the North Plant.

Indoors within the North Plant electrical room, a new 13.8kV North Plant switchgear shall serve the 4160V Chiller Substation and 480V Network transformers. In addition to replacing 4160V Substation A/B, 4160V Substation F/G shall also be replaced. These two substations shall be replaced by a single new 5000kVA double-ended 4160V substation for Chillers 2 and 3. The 480V Network transformers for Substation C/D/E shall also be replaced as part of the project, removing all three existing transformers and replacing with only two transformers and re-arranging the typical operation of Substation C/D/E to function like a typical main-tie-main switchgear with the tie breaker between bus C and bus D normally open. The tie breaker between bus D and bus E shall remain normally closed. This configuration of Substation C/D/E shall align with the existing and new upstream electrical distribution. The arrangement of the new equipment shall be re-orientated to facilitate the replacement of the 480V Network transformers and improve overall maintenance access.

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Figure 4 - New Simplified Single Line Diagram

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5. CONSTRUCTION PHASING

The installation of backup power distribution and electrical equipment replacement must be phased in a manner to maintain chilled water and hot water production to campus. Due to the electrical loading associated with chilled water production, the construction phasing must align with the chilled water production. Refer to Figure 5 for proposed phase execution relative to chilled water demand on campus. The blue rectangle overlays represent the capacity of each chiller in the South Plant. The red rectangle overlays represent the capacity of each chiller circuit in the North Plant. The description of anticipated work completed in each phase is indicated below. Design build contractor shall submit phasing plan including anticipated equipment outages for approval prior to commencing work. Any deviations from the construction phasing described in this section shall be noted.

Figure 5 - Campus Chilled Water Demand Overlayed with Construction Phasing

PHASE S1

All chillers in North and South Plant available to operate. Install all site work, ductbank, manholes and new outdoor electrical equipment, including backup generators, switchgear ESGCP, controls enclosure, load bank and padmount transformers.

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Phase S1 shall be completed by the start of the winter cooling season, typically early November.

PHASE S2

Only chillers in North Plant available to operate. De-energize the South Plant. Demolish feeders 106 and 205. Re-feed the new electrical distribution equipment from the existing B107 substation breakers 106 and 205. Start-up and commission the new electrical distribution equipment, control system and backup generators within the equipment yard.

Re-feed and re-energize the South Plant from switchgear ESGCP after commissioning.

Phase S2 shall be completed within the first two months of the winter cooling season.

PHASE N1

All chillers in South Plant and Chiller 3 in North Plant available to operate. De-energize and demolish 4160V Substation A/B. De-energize 480V transformer T-C and demolish 13.8kV cable feed from existing B107 substation. 480V Switchgear C-D-E only supported by transformers T-D and T-E.

Transfer all load at Building 102 to XFMR S1. Terminate new feeders from ESGCP2 at the available terminals at primary side transformer selector switches at Building 104 and TX-2.

Transfer load at Building 104 and TX-2 to the ESGPC2 source. Demolish Feeder 103.

Coordinate all outages with NIH.

PHASE N2

All chillers in South Plant and Chiller 3 in North Plant available to operate. Install switchgear SGCP2. Feed SGCP2 from switchgear ESGCP1 and ESGCP2. Start-up and commission switchgear SGCP2 and associated control system.

Terminate new feeders from ESGCP1 at primary side transformer selector switches at Building 104 and TX-2. Terminate new feeder from ESGCP2 at Building 102 XFMR S2 and transfer all load at Building 102 to XFMR S2. Coordinate all outages with NIH.

Phase N1 shall begin at the start of the spring shoulder season and Phase N2 shall be completed by the end of the fall shoulder season, typically April through October.

PHASE N3

Only chillers in South Plant available to operate. De-energize and demolish 4160V Substation F/G. Between phase N3 and phase N4 de-energize and replace one 480V Network Transformer at a time.

Demolish Feeders 101, 104, 201, and 202.

To ensure N+1 chiller capacity, Phase N3 shall not commence until the start of the following heating season, typically November.

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PHASE N4

Only chillers in South Plant available to operate. Between phase N3 and phase N4 de-energize and replace one 480V Network Transformer at a time. Install new 4160V Substation A/B. Feed Substation A/B from switchgear SGCP2. Start-up and commission Substation A/B and associated control system. Relocate VFDs for Chiller 2 and 3 and re-feed from Substation A/B. Test and Commission Chillers 2 and 3 and associated VFDs once permanent power is installed.

Terminate new feeder from ESGCP1 at Building 102 XFMR S1. Return Building 102 to normal configuration with load split across transformers XFMR S1 and S2.

Phase N4 shall be completed by the start of the following cooling season, typically July.

PHASE N5

All chillers in North and South Plant available to operate. De-energize and demolish existing 480V equipment ATS-2, ATS-3, ATS-5, PP-P6, PP-P5 and North Plant 480V generator.

Demolish existing ductwork and duct-mounted cooling coils and inline fan.

Some 480V demolition and new work in phases N5 and N6 may be coordinated and completed during phases N3 and N4. Note that VFDs for North Plant chillers 2 and 3 have tripped off due to overheating in the past when AHU-1 is offline. Coordinate with NIH operations so that capacity can be met without North Plant chillers when the North Electrical Room does not have both AHU-1 and AHU-2 in service.

PHASE N6

All chillers in North and South Plant available to operate. Install new panel PP-P5 and re-feed MCC-P3 and MCC-P4 directly from existing switchgear C-D-E. Install new HVAC equipment and ductwork.

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6. ENVIRONMENTAL

The design build contractor shall provide the following studies in compliance with the NIH Design Requirements Manual (DRM) to finalize generator exhaust stack height and enclosure sound attenuation and vibration isolation to limit impact to adjacent buildings on campus.

• Exhaust entrainment study

• Vibration study

• Noise study

• Air Permit Study

NIEHS Health and Safety Branch (HSB) shall complete the air quality permitting process with the State of North Carolina.

7. CIVIL & LANDSCAPE

The recommended site for the new equipment yard is located south of the CUP, between the building and the parking lot. The area just south of the building is utilized currently with a paved area with 3 loading dock bays. Just south of the paved area is a mounded berm with existing vegetation and trees (mainly pines) that are mature in height which together act as a physical security barrier. Refer to section 12 Security. At its peak, the mound of earth in this area is roughly 10’ higher in elevation than the surrounding pavement areas. Just south of the berm are 2 trailers that are currently being utilized by staff. The trailers are located south of the mound and just north of the parking lot. The site is supported by a network of utilities, including but not limited to underground power, communications, water, and stormwater appurtenances.

Power/light poles, signage, and large landscape boulders are also evident on the site. The site is centrally located and is not subject to any property setbacks and buffers, and there are no streams, wetlands, or environmental constraints associated with this area defined in magenta in Figure 6.

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Figure 6 - Enlarged Site Plan

SITE SURVEY, SUBSURFACE UTILITY EXPLORATION (SUE), AND

GEOTECHNICAL

The site has been surveyed as indicated in Figure 6. The survey consists of topography of the site, as well as the surface conditions in and around the site. The survey also locates existing utilities and inverts associated with accessible underground piping. In addition to traditional survey, subsurface utilities were also located and shown on the ultimate survey plan. In coordination with survey and to avoid underground utilities, geotechnical boring locations were also identified and drilled to identify the composition of the subsurface conditions. This geotechnical exploration shall aid the site design for new equipment and duct bank locations.

SITE GRADING AND DEMOLITION

The site shall be graded to minimize to the extent feasible the amount of impact to the natural terrain, existing drainage patterns, and environmental features. A substation amount of grade shall be taken off the mound that is located between the loading dock paved area and the parking lot. Existing trees shall be removed as necessary, and the earthen berm shall be cut down and taken to a destination agreed upon within the ultimate contract documents. Pavement/Concrete areas shall also be demolished and replaced in some areas to coordinate with new equipment and ductbank. The site shall be graded and constructed to allow the existing facility to function while new electrical distribution system is being constructed. The existing trailers shall be relocated and their supporting utilities shall be either relocated or demolished.

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DRAINAGE AND STORMWATER MANAGEMENT

The site shall be graded to minimize modifications to the existing stormwater system. The site shall comply with Article 8.0 of the City of Durham Unified Development Ordinance and Section 8.0 of the City of Durham Reference Guide for Development. The site shall be designed such that the post-development discharge rate and quantity does not exceed the pre-development discharge rate and quantity for the one-year, two-year, and ten-year, 24-hour design storms. Stormwater management facilities shall also be used to capture and treat the first inch of annual rainfall and provide 85% total suspended solids (TSS) removal.

Utilizing existing impervious surface on site for the construction of the new equipment yard or converting existing impervious to pervious or landscaped areas could negate the need for additional stormwater control measures.

EROSION AND SEDIMENT CONTROL

Erosion and sediment control shall be provided during the construction in accordance with the requirements of Durham County and the North Carolina Department of Environmental Quality and Design Manual and local codes. The erosion control measures shall consist of a combination of silt fence, silt fence outlets, diversion berms/ditches, and stormwater inlet protection as specified in the final design. The site was previously developed and wetlands, buffers, streams, floodplain, flood way, and open water exist on the overall parcel but not near the site. These environmental conditions have been avoided in the design of this project.

LANDSCAPING

All bare areas shall be stabilized with like grasses using sod. Boulders shall be strategically placed and utilized around the equipment yard to provide protection of the equipment. This physical security shall be placed in such a way to maintain equipment access and provide protection from day to day traffic and turning movements associated with existing traffic patterns.

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8. STRUCTURAL

For the new equipment yard, exterior foundation pads shall be provided for each generator, walk-in enclosure, and other outdoor equipment. Exterior concrete shall be designed to 4,500 psi, with allowable bearing pressure on residual soil designed to be 2,000 psi. Within the North Plant electrical room, the existing building slab shall be removed and replaced as required to coordinate with underground ductbanks and demolition of existing equipment pads. The replacement slab on grade shall be designed to 4,000 psi.

APPLICABLE CODES AND STANDARDS:

• NIH Design Requirements Manual (DRM)

• NIH Engineering Standards and Material Requirements (ESMR) – Revision H

• North Carolina Building Code – 2018 Edition

• North Carolina Existing Building Code – 2018 Edition

• International Building Code – 2015 Edition

• American Society of Civil Engineers (ASCE) 7-10

• American Concrete Institute (ACI) 318-14

• American Institute of Steel Construction (AISC) 360-10

DESIGN CRITERIA

Superimposed Dead Loads

• Weight of equipment TBD

Wind Load Criteria (ASCE 7-10)

• Design Wind Speed 120 mph (ultimate)

• Importance Factor (Iw) 1.0

• Exposure Category C

• Internal PressureCoefficient (GCpi) +/- 0.18

Seismic Load Criteria

• Spectral Response Accelerations SS = 0.156g S1 = 0.077g

• Spectral Response Coefficients SDS = 0.166g SD1 = 0.124g

• Importance Factor (Seismic Use Group II) 1.25

• Seismic Site Class(Presumed) D

• Seismic Design Category B

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MATERIALS AND METHODS OF CONSTRUCTION:

Concrete (f’c at 28 days) & Reinforcing Steel (Fy)

• Footings 3,000 psi

• Housekeeping Pads 3,000 psi

• Slab on Grade 4,000 psi

• Exterior Concrete 4,500 psi

• Deformed Reinforcing Bars 60,000 psi

Structural Steel(Fy) (If required):

• Wide Flange Shapes (ASTM A992) 50,000 psi

• Angles, Channels, Plates, Anchor Rods (ASTM A36) 36,000 psi

• Hollow Structural Sections (ASTM A500) 46,000 psi

• Bolts A325-N

• Welding Electrodes E70XX

Foundations

• Allowable Bearing Pressure: Footings and pads on Residual Soil 2,000 psf

• Coefficient of Friction Against Sliding (presumed) 0.30

9. MECHANICAL HVAC

GENERAL

Design of mechanical systems shall conform to requirements of the following standards:

Outdoor Design Conditions:

• Summer (Per NIH DRM):

o Dry-Bulb Temperature = 35°C (95°F) o Wet-Bulb Temperature = 25.6°C (78°F)

• Winter (Per NIH DRM):

o Dry-Bulb Temperature = -11.6°C (11°F)

Indoor Design Conditions for Electrical Room and Electrical Enclosures:

• Electrical Room:

o Temperature: 65°F Min / 85°F Max o Humidity: 60% RH Max

• Electrical Enclosures:

o Temperature: 65°F Min / 80°F Max o Humidity: 60% RH Max

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Heating and Cooling Loads:

• Occupancy o Electrical rooms are expected to be unoccupied except for operation and maintenance staff who periodically perform work in these enclosures. The mechanical systems serving these systems, however, shall be designed to operate 24 hours per day, 365 days per year.

• Building Envelope o Wall U value = 0.08 Btuh/sf-F o Roof U value = 0.05 Btuh/sf-F

HVAC Load Assumptions

• Internal Cooling Load o Electrical Room

▪ Total electrical equipment heat load = 40 Tons o Electrical Enclosures

▪ Heat load of equipment within enclosure determined by Switchgear Manufacturer and Enclosure Manufacturer

• Envelope Cooling Load o Electrical Room

▪ Heating = 30,000 Btu/hr envelope heat gain

Ventilation Rates

• Electrical Room o ASHRAE 62.1-2013 does not require ventilation to electrical equipment room.

APPLICABLE CODES AND STANDARDS

• 2018 North Carolina Mechanical Code

• ASHRAE American Society of Heating Refrigerating and Air Conditioning Engineers

• ASME American Society of Mechanical Engineers

• NIH Design Requirements Manual (DRM)

• NIH Engineering Standards and Material Requirements (ESMR) – Revision H

• Local Authority Having Jurisdiction (AHJ)

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PIPING, VALVES AND SPECIALITIES

The existing 2” and 3” diameter chilled water piping for cooling coils X-CC-1 and 2 shall be demolished.New pipe shall be installed to connect to the new air handling unit . New chilled water piping shall be welded in accordance with ASME 31.1 pressure class testing specifications. The new pipe materials shall be ASTM A53 Grade B, Type E standard weight, carbon steel for 2-1/2” and larger. The new pipe materials shall be ASTM B88 seamless, Type L, hard temper copper tube for 2” and smaller.

The new valves shall be installed and located to allow for the proper isolation and breakdown all equipment for periodic maintenance and complete equipment restoration. Ball Valves shall be provided for manual isolation valves, instrumentation isolation valves, drain valves and manual air vent locations. Automatic valves shall be characterized ball valve unless otherwise noted.

The piping system insulation materials shall have a hazard rating not to exceed 25 flame spread / 50 smoke developed. Insulation shall be continuous at all hangers, hanger rods, supports, sleeves, and openings. Refer to the specifications for additional details.

The pipe supports shall conform to MSS Standard Practice SP-58 (Materials, design and Manufacture), SP-69 (Selection and Application) and SP-89 (Fabrication and Installation Practices).

The new piping shall not be installed above electrical equipment. New piping installed above electrical equipment shall be approved by owner and have drip pan and drains below piping.

HVAC

Air Handling Units: The existing cooling coils X-CC-1, X-CC-2 and 26,000 CFM fan in the electrical room shall be demolished. The existing cooling coils and fan are oversized and are near the end of useful life. To improve efficiency, controllability, and maintenance a new air handling unit shall be provided. The electrical room shall be served by a vertical semi-custom single-zone variable volume air handling unit, AHU-2. The air handling unit shall be a semi-custom unit with chilled water-cooling coils. The AHU shall be return air units.

Filtration shall be MERV-8. Supply air shall be provided by direct drive plenum fans with electronically commutated motors for variable speed control. A new housekeeping pad shall be provided for AHU-2. Supply and return shall be ducted to provide proper distribution. The unit shall have (2) supply fans with electronically commutated motors. AHU shall consist of return air section, MERV 8 filters, chilled water-cooling coils, (2) supply fans and discharge air section. AHU airflow and chilled water coil shall vary in sequence to meeting the cooling load of the spaces.

Equipment Fan CFM Fan Size

HP

Chilled Water

EWT/LWT

Chilled Water Flow

AHU-2 12,000 15 HP 45⁰F / 59⁰F 56 GPM

Table 1 - AHU Performance Design Criteria

MV Vault Ventilation: MV Vault shall be served by a centrifugal sidewall exhaust fan EF-1.

The vault shall have a PVC pipe for intake air. The exhaust fan was sized based on 0.5

CFM/sf.

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Chilled Water Source: Chilled water shall be supplied at 44°F from the NIH Campus Central

Utility Plant (CUP) for HVAC demands. Secondary pumps shall be an inline style pump with packaged controller for variable flow operation.

Distribution

Chilled water shall be distributed through carbon steel piping with threaded fittings for pipes

2" and smaller and carbon steel piping with welded fittings for pipes 2-1/2" and larger.

Valves shall be installed and located to allow for the proper isolation and breakdown of all equipment for periodic maintenance and complete equipment restoration.

Ductwork

Ductwork systems shall be designed and fabricated per ASHRAE and SMACNA standards.

Noise levels, duct leakage, gains and losses shall be considered in the design and sizing of ductwork.

Insulation

Insulation materials shall have a hazard rating not to exceed 25 flame spread / 50 smoke developed. Insulation shall be continuous at all hangers, hanger rods, supports, sleeves, and openings.

Chilled water piping shall be insulated with expanded polyisocyanurate or foamglass insulation with appropriate insulation jacket.

• Interior Ductwork: 50mm (2 in.) thick Flexible Mineral Fiber, ASTM C 1290, Type III, FSK faced.

Supports

Pipe supports shall conform to and MSS Standard Practice SP-58 (Materials, design and

Manufacture), SP-69 (Selection and Application) and SP-89 (Fabrication and Installation

Practices).

Balancing Devices

Balancing dampers shall be provided at supply, return, and exhaust branch duct connections and at each supply, return and exhaust diffuser. In accordance with NIH RTP Engineering

Standards and Material Requirements, damper shall have singe blade 2 gauge thicker than the ductwork where it is installed. The damper blade shall be installed on a 3/8” steel rod of the same material type as the ductwork (galvanized, stainless, etc.) The rod shall extend through to a wingnut locking handle, that is offset outside the required insulation thickness without a locking quadrant nut.

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10. MECHANICAL FUEL OIL

The existing fuel system in Building 105 consists of two 120,000-gallon (108,000 gallon nominal) fuel oil tanks located in a diked containment area on the southwest corner of the building. High fuel level is limited to 90% capacity per the Spill Prevention, Control, and Countermeasure (SPCC) rule established by the Environmental Protection Agency (EPA). Two sets of positive displacement fuel oil pumps with one set in the north end of the plant and the other in the south end of the plant serve the existing high temperature hot water (HTHW) generators and 480V backup power generators. The system is piped with carbon steel piping and valved such that either tank can serve either set of pumps. The system is equipped with a backpressure regulating valve in front of HTHW generator B-4 to protect the system from over pressurization. The backpressure valve shall remain unchanged by this project.

The south set of pumps serve two existing HTHW generators B-4 and B-5. Each HTHW generator is rated at 40MMBtu output with a fuel oil input of 367 gallons per hour or 6.12 gallons per minute. HTHW generator efficiency is calculated as 79% when firing on oil.

The existing pumps set serving HTHW generators B-4 and B-5 shall be utilized to serve the new 13,800V backup power generators. One existing 480V backup power generator being served by this pump set shall be removed as part of this project. In the future when two additional new backup power generators are installed it is expected that the second existing 480V backup power generator either be removed as part of a future project or not operate concurrently with the four 13,800V backup power generators. Therefore, the existing 480V backup generators are not required to be calculated as part of the available fuel oil pumping capacity.

The pump set serving HTHW generators B-4 and B-5 is rated at 3,120 gallons per hour or 52gpm. The proposed new 13,800V backup power generators each consume 173 gallons per hour of fuel at full electrical output capacity. When four 13,800V backup power generators are installed the total fuel consumption at full electrical load is 704 gallons per hour or 11.7 gallons per minute.

With the HTHW generators and four 13,800V backup power generators at maximum load capacity and consuming the maximum fuel, the fuel consumption would be 1,438 gallons per hour or 24 gallons per minute and the existing fuel pump skid can accommodate this capacity without modification.

Each of the new 13,800V backup power generators shall be equipped with a 5,000-gallon sub-base tank. The new fuel line to each tank shall be equipped with a solenoid valve and union orifice which shall fill the tanks at 8 gallons per minute. At full electrical load, each generator consumes 2.93 gallons per minute so each generator’s sub-base tank fills at a rate of just over five gallons per minute.

At 8 gallons per minute fill rate for each generator, the existing pump skid can sufficiently fill the two new sub-base tanks as well as the future two sub-base tanks simultaneously while still serving 100% capacity to HTHW generators B-4 and B-5 with some excess available for backpressure recirculation.

APPLICABLE CODES AND STANDARDS:

• NIH Design Requirements Manual (DRM)

• NIH RTP Engineering Standards and Material Requirements (ESMR) – Revision H

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• NFPA 30 Flammable and Combustible Liquids Code

• NFPA 30A Code for Motor Dispensing Facilities

• Local Authority Having Jurisdiction (AHJ)

PIPE SIZING

The piping to serve the generator sub-base tank fill must be sized for 32 gallons per minute or 1,920 gallons per hour. This fill rate assumes filling the two new tanks as well as the two future tanks simultaneously.

Typical diesel fuel has an SSU of approximately 100 at 50 degrees F. The charts below utilize the SSU of 100 for pressure drop calculation.

Pressure drop chart for 1-1/2” pipe is shown in figure 7A below. At 32 gpm of fuel using 100 SSU, the pressure drop would be approximately 5.5 psig per 100 ft of pipe. The length of 1- 1/2” pipe is approximately 200 ft so the future maximum pressure drop is 11psig. Pressure drop chart for a 2” pipe is shown in figure 7B below. At 32 gpm of fuel using 100 SSU, the pressure drop would be approximately 1.8 psig per 100 ft of pipe. The length of 2” pipe is approximately 100ft so the future maximum pressure drop is 1.8 psig. The total future pressure drop would be 12.8 psig. Since the pump supply pressure is 100psig and the tank being filled is at atmospheric pressure, 12.8 psig of pressure drop is acceptable. The underground piping between the transition sumps is reduced to 1-1/2” in size to accommodate the pressure rating required for the underground containment piping.

Figure 7A – Pressure Drop Chart (1-1/2”Pipe)

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Figure 7B - Pressure Drop Chart (2”Pipe)

PIPE MATERIALS

Fuel oil systems constructed from threaded fittings and valves have issues with leaks at each joint. As such, carbon steel piping for above ground and interior spaces is recommended with socket welded fittings and valves. Provide 3000# socket welded fittings and Jamesbury Firetite(or equal) carbon steel body ball valves. Valves shall be full port with socket weld ends. Solenoid valves should also be Jamesbury Firetite or equal.

Underground piping is required to be double wall containment piping. Piping must be rated for minimum of 100psig working pressure. Outer containment piping must be rated for minimum of 50psig. All underground piping should be continuous without joints in the primary piping or containment piping. OPW Flexworks piping or equal, such that corrosion protection is not required.

Transition from double wall piping to carbon steel piping at both ends with a code compliant transition sump. Provide leak detection system at each transition sump including performance certification from the manufacturer. Provide a solenoid valve just prior to interior piping leaving Building 105 for fuel isolation in the event of a leak detection alarm in accordance with AHJ. Valve may be solenoid or fusable link as AHJ allows. If fusable link is allowed, no connection to the leak detection system is required.

All materials and methods shall adhere to NFPA-30, NFPA-30A and local authority having jurisdiction. Requirements by these entities may be more stringent than shown on drawings.

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CONTROL SEQUENCING

The existing building automation system (BAS) uses the ABB Symphony Plus – DCS architecture and currently controls the fuel oil pumps. The new generators shall be integrated with the existing BAS to accomplish the following sequence. The existing generator sequencing shall be removed once the new generators are installed and integrated into the BAS. The BAS shall be updated with new graphics for the new generators and graphics for the old generators removed.

The new generators are equipped with 5,000 gallon sub-base tanks with a “full” capacity of 4,500 gallons (90%) and a maximum limit of 4,750 gallons (95%).

When a generator starts, the generator control panel shall send a signal to the BAS and the lead fuel oil pump shall start. If the existing HTHW generators B-4 and B-5 are operational on oil, a fuel pump would be running. Any excess fuel oil would recirculate through the existing backpressure regulating valve.

When the fuel level in a generators sub-base tank reaches a low level of 2,500 gallons (Field Adjustable (FA)) the respective solenoid valve on the fuel oil supply line shall open.

The union orifice shall then allow 8 gallons per minute to fill the sub-base tank until the generator reaches its full capacity of 4,500 gallons (FA).

Should the generator shut down prior to reaching full capacity of 4,500 gallons (FA), the fuel pump shall continue to operate until the generators sub-base tank is full. Once the sub-base tank is full, its respective fuel solenoid valve shall close and a signal shall be sent to the BAS to stop operation of the fuel pumps. If HTHW generators B-4 or B-5 is operational on fuel oil, the fuel pump shall continue to operate.

At any time if either leak detection system indicates a fuel leak, the fuel solenoid valve at the exit of building 105 shall close (as applicable) and a leak alarm shall be initiated at the BAS.

If HTHW generators B-4 and B-5 are not utilizing fuel oil, any operating fuel oil pump shall stop. If HTHW generator B-4 or B-5 is operational on fuel oil, the operating fuel oil pump shall continue to operate and the solenoid valve leaving building 105 shall close. A leak alarm shall be initiated at the BAS.

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FUEL OIL RUN-TIME CALCULATION

Fuel Oil Storage Capacity

B105 Fuel Oil Tank #1 108,000

B105 Fuel Oil Tank #2 108,000

Generator 1 Sub-Base Tank 4,500

Generator 2 Sub-base Tank 4,500

Total Gallons 225,000

Fuel Oil Consumption (Worst Case) GPH

HTHW Generator B-4 367

HTHW Generator B-5 367

Generator 1 173

Generator 2 173

Future Generator 3 173

Future Generator 4 173

Total 1,426

Run-Time Hours 157.8

Run-Time Days 6.6

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11. FIRE SUPPRESSION

The…