Att B_CUP POR.pdf

National Institute of Standards and Technology

Program of Requirements for

Central Utility Plant Facility June 2024

Metropolitan Architects and Planners, Inc.

with A f f i l i a ted Eng ineers , Inc . , and A lpha Corporat ion

P r o g r a m o f R e q u i r e m e n t s

J u n e 2 0 2 4 i

Table of Contents

1. Project Summary A. Project Goals B. Background and Existing Conditions

1) Central Utility Plant Overview

2) Existing Utility Costs

3) Economic and Emission Factors

C. Projected Needs and Phasing D. Requirements Summary

2. Project Context A. Site Context B. Existing Conditions Assessment

1) Building

2) Chiller Plant

3) Steam Plant

4) Cogeneration Plant

5) Electrical

6) Additional CUP Improvements

7) Condition Assessment Summary

3. Program Analysis A. Campus Utility Energy Model

1) Methodology

2) Existing Building Utility Loads

3) Existing Plant Production

4) Future Building Loads

5) Energy Performance Model

B. Thermal Options

1) Chiller Plant Options

2) Steam / Hot Water Generation Options

C. Summary

4. Architectural Approach

A. Structure

1) Structural Considerations

2) Structural Approach

B. Site and Civil

1) Site Improvement Approach - Site Demolition

2) Pedestrian Circulation Systems

3) Vehicular Access and Pavements

4) Topography, Grading, and Drainage

5) Landscaping

C. Site Utilities Approach

1) Potable Water

2) Sanitary System

3) Storm Drain System

4) Site Electrical

5) Site Telecommunication and Communications Signal

6) Gas

7) Chilled Water

8) Steam

9) Compressed Air

N a t i o n a l I n s t i t u t e o f S t a n d a r d s a n d T e c h n o l o g y

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D. Fire Protection

1) Approach

2) Standpipe System

3) Wet Pipe Sprinkler System

E. Stormwater Management

1) Overview of Hydrologic Conditions

2) Overview of Soil Conditions

3) Stormwater Management Treatment

4) Stormwater Management Opportunities/Environmental Site Design (ESD) Options

5) Stormwater Management Challenges

F. Digital Services / Low Voltage Systems (IT, Telecom, Security, AV)

1) Site Approach

2) Building 302 and Expansion Approach

3) Command Center Approach

4) Information Technology Systems

G. Applicable Codes and Standards

5. Room Data Sheets

6. Abbreviations

7. Performance Criteria Performance Criteria – New Construction

A. Substructure A10 Foundations A20 Basement Construction

B. Shell B10 Superstructure B20 Exterior Enclosure B30 Roofing

D. Services D20 Plumbing

D2010 Domestic Water Distribution D2020 Sanitary Drainage D2030 Building Support Plumbing Systems D2050 General Service Compressed-Air

D30 Heating, Ventilation, and Air Conditioning (HVAC) D3010 Facility Fuel Systems D3020 Heating Systems D3030 Cooling Systems D3050 Facility HVAC Distribution Systems

D40 Fire Protection D50 Electrical

D5010 Facility Power Generation D5020 Electrical Service and Distribution D5030 General Purpose Electrical Power D5040 Lighting D5080 Miscellaneous Electrical Systems

D80 Integrated Automation D8010 Integrated Automation Facility Controls

Performance Criteria – Existing Building A. Substructure

A10 Foundations A20 Basement Construction

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B. Shell B10 Superstructure B20 Exterior Enclosure B30 Roofing

C. Interiors C1030 Specialties Acoustical Criteria

E. Equipment and Furnishings E30 Structured Voice & Data Cabling Infrastructure E40 Security System Infrastructure E50 Audiovisual Systems & Infrastructure

F. Special Construction and Demolition F20 Hazardous Components Abatement

G. Building Sitework G10 Site Preparation G20 Site Improvements G50 Site Civil Utilities

Appendices

(under separate cover)

Appendix 1: Requirement Summary and Associated Drawings

Appendix 2: Exist ing Conditions

Appendix 3: Code Observations

Appendix 4: Site Information

Appendix 5: Charrette Report

Appendix 6: Estimated Uti l i ty Loads

Appendix 7: Option Analysis Support Information

Appendix 8: NIST Documents A. Direct Digital Control System Specifications B. Network and Telecommunication Infrastructure Standards C. Security and Access Control Standards D. Building Security Guidelines E. Construction Security Plan F. Fire Protection and Life Safety for Design and Construction

Projects – Use and Occupancy Requirements G. AV Equipment Requirements for Collaboration Spaces H. Design Process and Space Guidelines for Non-Laboratory Space I. Contractor Required Items for Certificate of Occupancy J. Division 1 Specifications

Appendix 9: A/V Equipment List

Appendix 10: Proposed Util i ty Plan (Schematic)

Appendix 11: Geotechnical Engineering Report iv Metropolitan Architects and Planners, Inc. | Affiliated Engineers, Inc. | Alpha Corporation

Location of Central Utility Plant, NIST Gaithersburg Campus

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1. Project Summary

The National Institute of Standards and Technology (NIST) headquarters campus is located on 579 acres in Gaithersburg, Maryland. The original campus construction dates from the early 1960s and the entire campus has been designated a National Register Historic District. NIST has embarked on a program to expand and modernize its facilities on its Gaithersburg campus. The 2018 NIST Gaithersburg Campus Master Plan and Environmental Assessment identifies the need to renovate more than 2 million gross square feet (GSF) and add more than 1 million GSF in new construction. The Central Utility Plant (CUP) modernization and replacement of underground utilities are necessary to allow the work described in the Master Plan and support the overall mission of NIST. The activities are interrelated. This project is to optimize the infrastructure at NIST’s Gaithersburg campus for the future and must explore available opportunities to improve sustainability and resiliency to meet the requirements identified in Executive Order (EO) 14057 Catalyzing Clean Energy Industries and Jobs through Federal Sustainability.

The CUP includes Building 302 - the Steam & Chilled Water Generation Plant (B302), Building 305 - Cooling Tower (B305), Building 305V - Electrical Service Building (B305V), Building 306 - Electrical Substation (B306), Building 316 - Electrical Service Building (B316), and Building 317 - Cooling Tower (B317).

A. Project Goals

The CUP modernization is aimed at providing a much-needed boost to the capacity and reliability of utilities that serve the entire NIST campus. These utilities are critical for the operation and functioning of all laboratories, support, and administrative facilities that support the NIST mission.

The intent of this Program of Requirements (POR) document is to offer a comprehensive package to allow accurate proposals from selected design-build entities. Design and implementation for the CUP’s modernization shall follow these project goals:

Maintain campus operations during modernization through a logical sequence of small phases of construction. Any impacts on campus research activities need to be minimized.

Implement sustainable design principles, embracing NIST’s environmental commitment, including principles established in the NIST Sustainable Design Manual and approaches recommended in the Campus Master Plan.

Deliver a high performance, energy efficient building, integrating considerations of climate impact, resiliency, natural environment responsibility, and the well-being of the occupants.

Enhance the landscape, blending with existing landscape elements, and integrating stormwater management best practices.

Compliance with requirements of EO 14057 to achieve net-zero emissions.

Respect the campus National Register Historic District designation in the building design and landscaping and adhere to the Secretary of the Interiors Standards for new construction within historic districts.

Equipment selection, installation processes, and a comprehensive direct digital control monitoring system should provide a state-of-the-art facility that ensures reliability and redundancy.

B. Background and Existing Conditions

The Gaithersburg campus houses approximately 3,600 scientists, researchers and other staff housed in over

3.7 million gsf of constructed area. Its stock of 27 laboratory facilities includes special purpose buildings designed to service unique research functions, and adaptable general-purpose laboratories to support a variety of research needs. Several advanced lab facilities have been added over time. The Central Utility Plant

2 Metropolitan Architects and Planners, Inc. | Affiliated Engineers Inc. | Alpha Corporation and the campus-wide distribution network provide critical infrastructure required for the Institute to fulfill its mission. Appropriately the CUP Building 302 was the first campus facility to be completed. In its current operations, the CUP also includes five small support service structures and facilities.

Most of the utility distribution network is original to the campus, now some 60 years old. NIST intends for these vital facilities to be modernized and expanded and the distribution to be replaced. The total capacity of infrastructure services currently needed exceeds that of the original installations. When modernized or replaced, these facilities should account for future growth of the campus, mostly in alignment with Phase 1 and 2 of the current Master Plan, and other programs that NIST is planning to pursue. This document defines the requirements for the upgrade and renovation of various components of the CUP. It is a high priority for NIST and the work is expected to be initiated in the near future. The NIST Master Plan is the guiding document for the future development of the campus. The current master plan is posted on the NIST website at https://www.nist.gov/ofpm/nist-gaithersburg-master-plan. The entire NIST campus is listed in the National Register of Historic Places as a historic district. The CUP is a contributing resource to the historic district and must comply with the Secretary of the Interior’s Standards for construction within Historic Districts and the Section 106 requirements. It will be subject to review by the Maryland Historical Trust, as well as NCPC, the NIST Federal Preservation Officer and the NIST Architectural Design Review Board. New landscaping must respect the originally designed campus landscape features, which are contributing elements to the historic district.

The CUP modernization must embrace NIST’s commitment to sustainable design. The sustainability goals for this project are driven by a combination of environmental commitment, legislation, regulation, and executive orders The design and construction must meet federal regulations for energy and sustainable design, as well as reinforce NIST’s commitment to environmental responsibility. Key requirements include LEED Gold certification by the US Green Building Council as a minimum, as is compliance with the Guiding Principles for Sustainable Federal Buildings. Meet requirements of Executive Order 14057, Catalyzing Clean Energy Industries and Jobs Through Federal Sustainability, to the extent possible. The Design-Build Team will develop the strategies, provide the documentation, and coordinate the submission for these programs.

The NIST Gaithersburg campus has a security rating of FSL-III (Facility Security Level), as designated by the Interagency Security Committee (ISC). This level is the base line level of protection for individual buildings.

Modernization of the CUP must comply with the requirements of ISC Appendix B: Countersecurity Measures, Facility Security Level III—part of the document The Risk Management Process: An Interagency Security Committee Standard (current version). The Design-Build Team will work with NIST’s Emergency Services Office (ESO) to confirm the FSL at the time of design and determine the final measures required. See the Appendix “NIST Security and Access Control Standards” for more information on NIST standard security systems hardware and installation requirements.

1) Central Utility Plant Overview

The CUP, located in Building 302, includes three primary sub-plants including the Chilled Water Plant, the Steam Generation Plant, and the Combined Heat and Power Plant. A floor plan indicating the plant sub-sections is presented in Figure 1.B.1.

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Figure 1.B.1: Existing CUP Ground Level Floor Plan

a. Existing Chilled Water Plant

The Chilled Water Plant includes seven chillers each with a rated capacity of 3,500 tons of refrigeration for a total capacity of 24,500 tons. A summary of the existing chillers is presented in Figure 1.B.2.

Figure 1.B.2: Existing Chiller Summary

Plant personnel have indicated a number of chillers are derated primarily due to age and condition.

Several chillers can only produce a maximum 3,200 tons, reducing the total operating capacity of the chillers to 23,000 tons as indicated in Figure 1.B.2.

Chiller Nos. 5 and 6 are operated by Johnson Controls, Inc. (JCI) under an Energy Savings Performance Contract (ESPC). JCI has also implemented a dispatch methodology for the chilled water generation system to optimize efficiency.

Not to scale

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The CUP chilled water pumping is a primary / secondary configuration. All chilled water pumps utilize variable frequency drives (VFD). The primary chilled water pumps are located on the lower level of the chiller plant below a grated access. The condenser water pumps are constant speed, vertical turbine pumps located outside adjacent to the cooling towers. A summary of the chilled water and condenser water pumps is presented in Appendix 2.

The heat rejection for the chillers is satisfied by two cooling towers designated as CT-305 and CT-

317. CT-305 is comprised of eight cells with a total capacity of 23,000 tons, and CT-317 includes two cells with a total capacity of 3,500 tons. CT-305 serves Chiller Nos. 1-6 and CT-317 serves Chiller No. 7 and the two free cooling heat exchangers. A summary of the cooling towers is presented in Appendix 2.

During the shoulder and winter months the CUP utilizes two free cooling (FC) heat exchangers each with a capacity of 2,000 tons. The FC system is operated when the outside air temperature falls below 37°F. Typically, the system generates between 2,500 tons and 3,000 tons.

b. Existing Steam Generation Plant

The steam generation system includes six boilers and one Heat Recovery Steam Generator (HRSG).

The units generate and distribute 150 psig saturated steam. A summary of the steam generation equipment is presented in Figure 1.B.3.

Figure 1.B.3: Existing Boiler Summary

Similar to the chilled water generation system, the existing boilers have difficulty achieving maximum capacity rating at peak load periods. The operating capacity column represents the peak output of the boilers based on feedback from NIST plant personnel. The total operating capacity is 388,000 pounds per hour (pph).

The firm capacity is considered under two scenarios – 1. With natural gas and fuel oil available, 2.

With only fuel oil available. With both fuels available, the firm capacity is the total capacity minus the largest steam generation asset which is the HRSG. The resulting firm capacity is 308,000 pph.

Under Scenario No. 2, if natural gas is curtailed or unavailable, the combustion turbine and HRSG systems will be offline. With only fuel oil available the firm capacity of the steam generation system is further reduced to 234,000 pph.

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c. Existing Combined Heat and Power Plant

The Combined Heat and Power (CHP) Plant is located adjacent to the steam generation plant. It consists of a Solar Taurus 70 combustion turbine generating a nominal 8.0MW of electrical power. A HRSG utilizes the exhaust gas from the combustion turbine to generate approximately 36,000 pph of steam. The combustion turbine exhaust gas temperature can be elevated by supplemental firing of natural gas using a duct burner. The duct burner increases the steam generation to approximately 80,000 pph.

The combustion turbine and duct burner are natural gas fired only. The CHP system is part of the JCI ESPC along with Chiller Nos. 5 and 6.

2) Existing Utility Costs

The utility billings for the CUP were evaluated for fiscal years 2019 through 2023. The billings included natural gas, electric, and water/sewer. The electric costs from the utility include separate commodity and distribution charges. The commodity is currently supplied by American Electric Power (AEP) Energy and the distribution charge is from the Potomac Electric Power Company (PEPCO). Both charges include a demand cost and a usage cost; however, the billings for AEP Energy do not differentiate between the two costs, only providing a total usage cost. PEPCO Tariff demand charge is applicable in the summer months only.

PEPCO Distribution Demand Cost: $2.595 / kW

PEPCO Distribution Usage Cost: $0.0424 / kWh

AEP Energy Commodity Cost: $0.0734 / kWh

A summary of the electric costs for 2019 through 2023 is presented in Figure 1.B.4.

Figure 1.B.4: Electric Billing Summary

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Similarly for natural gas, both commodity and distribution are purchased from different utilities. Novec Energy supplies the commodity and Washington Gas provides the distribution. A summary of the natural gas charges for 2019 through 2023 is presented in Figure 1.B.5.

Figure 1.B.5: Gas Billing Summary

Washington Suburban Sanitary District (WSSD) provides the water supply to NIST. A summary of the water billings from 2019 through 2023 is presented in Figure 1.B.6.

Figure 1.B.6: Water Billing Summary

For the economic analyses in this report the following 2023 utility costs were used. Electric demand and usage charges were applied separately as each component affects the analyses differently.

Electric (demand) .............. $2.595 / kW

Electric (usage) ................. $0.1158 / kWh

Electric (average) .............. $0.1217 / kWh

Natural Gas ..................... $5.60 / Decatherm

Water .............................. $7.71 / 1,000 Gallons

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3) Economic and Emission Factors

The present value factors utilized in the following life cycle cost analyses are based upon the 2023 Energy Price Indices and Discount Factors for Life-Cycle Cost Analysis: Annual Supplement to NIST Handbook

135. The 2023 OMB discount rates for Census Region 3 (commercial) were used for non-fuel, electric and natural gas for a 25-year term:

Non-Fuel PVF ..................................... 19.52

Electric PVF ......................................... 17.28

Natural Gas PVF ................................. 17.48

In addition, Tables D-1 through D-3 list carbon dioxide equivalent emission rates for fuels and electricity by state as well as emission prices and rate indices. The emission rates listed for Maryland are:

Electric Emission Rate .......................... 1.08 lbs CO2e / kWh

Natural Gas Emission Rate .................. 130.3 lbs CO2e / MMBtu

Note: 1.0 MMBtu = 1,000,000 Btu

Utilizing the 3% discount rate carbon policy scenario which represents assumptions that best align with the Department of Energy (DOE) and OMB discount rates, the current carbon cost is $0.0262 / lbs CO2e.

The emission rate for natural gas is assumed constant over time whereas the emission rate for electricity is adjusted for changes in the fuel mix in the electric grid. For a 25-year term the projected present value factors are:

Electric Emission Cost PVF ................... 21.31

Natural Gas Emission Cost PVF ........... 32.94

C. Projected Needs and Phasing

NIST’s foray into ground-breaking research areas requires facilities with state-of-the-art environmental and laboratory services. These include chilled water (supply and return) for cooling, high pressure steam and condensate for heating, electrical power, water, natural gas, and signal and communication for information technology and security needs. Several of these services are provided by the central utility plant.

All modernization and new construction efforts at NIST strive for high-efficiency systems that simultaneously achieve the lowest possible carbon footprint. NIST positions itself to exceed industry standards and federally mandated requirements for system efficiencies and sustainability.

There are several characteristics and functional requirements that will be embraced by CUP modernization, including:

Design Complexity. Many considerations - functional efficiency, energy management, security, and above all the implementation strategy - influence the approach to this project. These considerations require a macro perspective to establish priorities and direction for design.

Crafting a Practical Plan. The reliability of utilities is extremely critical to the laboratories and technical infrastructure throughout the campus. The continuity of operations of the CUP and utility distribution shall, of necessity, be a dominant factor in all design and construction decisions.

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Green, Low-Carbon Development. NIST is at the forefront of research in net-zero buildings and low-carbon development. Integrating energy innovations is a collaborative process. The renovation and design of the facility should employ a variety of active and passive strategies that reduce dependence on fossil fuels.

Design Guidelines Compliance. The Gaithersburg Campus Master Plan established design guidelines for the entire campus that must be implemented, and conformance verified.

Establishing the Requirements. The core program is the delineation of spaces and development of technical requirements that support and enhance the CUP functions.

Modernizing within the Historic Context. The Gaithersburg campus is designated as a Historic District and all renovation and new construction must be reviewed by the National Capital Planning Commission, the Maryland Historic Trust, and NIST’s Architectural Design Review Board. The CUP modernization approaches the design aesthetic with a sensitivity to the historic context.

Build America Buy America Act requires federal construction projects to use domestically produced materials. This stipulation should be followed and any exceptions will require prior approval from the Government.

D. Requirements Summary

The CUP modernization is programmed in stages to facilitate the effort without disruption to ongoing services and for funding availability over multiple fiscal years. This POR includes a detailed life cycle cost analysis of multiple options to address future expansion and current CUP deficiencies. Three 10-year phases have been delineated for the long-term action plans in the analyses.

The requirements for the POR include the recommendations outlined under the selected approach for the first two phases (20-year). The early phases of the D-B contract should prioritize the 1st 10-year work for the early construction phases and the 10-20 year work for the later construction phases. Tasks in the first phase are labeled as REQUIREMENTS and tasks under the second phase are labeled as ADD ALTERNATES. Under both phases are projects labeled as ENHANCEMENTS that may be selected to be part of the scope. The tasks also include recommendations based on the CUP condition assessment.

The recommended option for the chilled water system is Option No. C-5 which includes a new Thermal Energy Storage (TES) tank and replace-in-kind chillers for Chiller Nos. 1 through 4 of the CUP. Replacement of auxiliary equipment (cooling towers, chilled water pumps and condenser water pumps) as well as select piping segments are also recommended. Additional secondary pumps may require expansion of the CUP.

An alternate requirement would be to increase the capacity of the replacement chillers to 4,000 Tons thus deferring additional new chillers in the future and maximizing the available space in the plant.

To support the expansion of the chilled water system, new electrical distribution equipment will be phased in.

The new electrical equipment will include a 13.8 kV Switchgear lineup to support all new chillers, a 4.16 kV substation to support all new pumps larger than 400 HP, and new 480/277V spot-network substations to support all the low-voltage equipment loads. A new electrical building to house the medium-voltage switchgear for the chillers and pumps is also recommended.

The recommended option for the steam system is Option H-4 which includes replacement boilers in the CUP as well as several auxiliary systems and piping. The new boilers will be high efficiency dual fuel units burning natural gas and fuel oil.

Several options were considered to reduce fossil fuel usage per EO 14057 including electric boilers, hot water generators, heat pump chillers, and geothermal heat pumps. The recommended Options C-5 and H-4 ultimately include heat pump chillers and hot water generation systems; however, this technology cannot be implemented until the NIST campus buildings are converted to hot water use and a new hot water distribution

June 2024 9 system is installed. Thus, the additional heat pump chillers are recommended under the third phase of implementation (21-30 years) and are not part of this POR.

Replacement steam generation equipment is required prior to the completion of a campus wide hot water conversion. The new boilers are more efficient than the existing units by approximately 4% reducing the carbon dioxide equivalent emissions by approximately 3,000 MTCO2e. The new heat pump chillers and hot water generation system are anticipated to be implemented in Phase 3 and not part of the POR requirements.

Once the hot water conversion is complete and heat pump chillers are installed, it is estimated the local CUP carbon dioxide equivalent emissions will be reduced by 30,800 MTCO2e.

Electric boilers were considered, but due to the size would require a significant upgrade to both the NIST campus and PEPCO electrical utility infrastructure. In addition, the annual electrical cost would be approximately five times the natural gas cost for the boilers equating to an increase of approximately $18 million per year.

Supplement site plans, schematics and equipment details for the POR are located in Appendix 1.

A summary of the requirements and enhancements of this POR are presented in Figure 1.D.1 as well as in Appendix 1.

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Figure 1.D.1: Requirement and Enhancement Summary

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Architectural requirements to suport this modernization effort include:

Chiller wing addition – high bay space

Pump room addition – high ceiling space

New electrical building

New chilled water thermal energy storage tank

New central storage/warehouse space for equipment parts

Central Command and Control room

Chief’s office and a meeting room

Employee support areas including a break room, kitchen, and bunk space

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2. Project Context

NIST’s capital improvements program is an ongoing effort to facilitate the scientists to continue with their breakthrough achievements in technology by providing new and renovated modern research facilities. To service these facilities the CUP must be modernized to ensure that all utilities are available at required capacities. The operations of the CUP should meet or exceed industry-accepted central plant performance metrics.

A. Site Context

The CUP complex comprises of Buildings 302, 305, 306, 316, and 317 and the PEPCO substation, and is located at the corner of West Drive and South Drive. It has direct access via Gate D on Quince Orchard Road west of the campus. While equipment and systems upgrades are central to the CUP modernization effort, Building 302 may be expanded on the west and north to house new equipment and a portion of the administrative and support spaces may be enhanced with a small addition. All utility lines emanate from this complex. The Appendices in this POR document include a CUP site plan and an existing utilities distribution plan for the campus.

Photo 2.A.1: Interior Courtyard of 302 Looking East

Photo 2.A.2: 302 Courtyard Looking Northeast

Photo 2.A.3: 302 Steam and Chiller Wings

Photo 2.A.4: 302 Steam Wing & Cogen Facility

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Photo 2.A.5: 316 and 317

Photo 2.A.6: 302 Administrative Block

Photo 2.A.7: Cooling Towers (305 and 317)

Photo 2.A.8: Cooling Towers (305)

Photo 2.A.9: Temporary storage, infill area

Photo 2.A.10: Building 306 and PEPCO Substation

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B. Existing Conditions Assessment

A condition assessment was performed of the utility plants at the NIST campus in Gaithersburg, Maryland. The campus consists of a Cogeneration Plant, Steam Plant, and Chilled Water Plant. Field surveys were conducted in July 2023 to visually assess the equipment, piping systems, and general operation.

The following Condition Assessment Report evaluates the existing equipment, identifies potential areas for improvement, and provides recommendations to modernize or repair the major equipment and piping systems located in the plants.

The global assessment was developed by performing the following tasks:

Visual assessment of major equipment both idle and operating

Surface temperature, noise, and vibration observation of operating equipment

Visual inspection of general plant auxiliary systems

General discussions with plant Operating and Maintenance personnel

The primary purpose of the site investigations is to determine the condition of the existing equipment and piping systems and estimated useful equipment life as well as to develop a preliminary understanding of the plant operations and dispatch methodology.

The existing equipment condition was rated as Poor, Fair, Good, and/or Excellent. The rating system reflects the physical age and condition of the equipment as well as the estimated remaining useful life. The overall assessment process is subjective since equipment was not dismantled. The assessment rating was determined utilizing common industry standards, similar project experience, and basic manufacturers’ recommendations.

Equipment Rating Remaining Useful Life

Poor < 5 years

Fair 10 years

Good 20 years

Excellent 30 years

The following equipment was surveyed under this report:

1. Chiller Nos. 1 – 7 14. Continuous Blowdown Tank & Heat Exchanger

2. Primary Chilled Water Pumps (8) 15. Bottom Blowoff Tank

3. Secondary Chilled Water Pumps (4) 16. Water Softeners (4)

4. Cooling Tower Nos. 1 & 2 17. Condensate Polisher

5. Condenser Water Pumps (8) 18. Chemical Treatment System

6. Free Cooling Heat Exchangers (2) 19. Fuel Oil Pumps (2)

7. Free Cooling Pumps (2) 20. Compressed Air System

8. Condenser Water Sand Filters (4) 21. Gas Turbine

9. Boilers No. 1 – 6 22. Heat Recovery Steam Generator

10. Deaerators (2) 23. Natural Gas Compressor System

11. Boiler Feedwater Pumps (3) 24. Cogen Glycol Cooling System

12. Condensate Receiver 25. Cogen Compressed Air System

13. Condensate Pumps (2)

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1) Building

Building 302 together with the electric sub-station was the first facility to be commissioned. The basic architecture and infrastructure systems of the building have remained generally intact, though the current configuration is larger than the original structure: The chiller wing was expanded in 1994 for two additional chillers and in 2011 for the seventh chiller. The latter was in conjunction with the addition of the Cooling Tower 317. The steam generation wing added two boilers in 1998, and a Combined Heat and Power (CHP) was added in 2019. The facility is now about 60,000 gross square feet. The Plant building is primarily a single level high-bay structure. Some equipment needs result in creation of pits, mezzanines or step-down floor levels. The CHP area has some support elements on the second floor.

At the node of the two primary wings is the entry to the facility where offices and employee amenities are located. The building has benefitted from the window replacement program at NIST wherein high efficiency double pane low-e windows have been installed. Proximate to the facility are the cooling towers. Large high-pressure pipes originating from this facility deliver steam and chilled water to all buildings on campus for their heating and cooling requirements.

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2) Chiller Plant

The existing chilled water plant currently consists of seven 3,500-ton chillers for a total installed capacity of 24,500 tons. Auxiliary supporting equipment includes three cooling towers (10 cells), two free-cooling heat exchangers with associated pumps, eight chilled and condenser water pumps, four secondary chilled water pumps, and condenser water sand filters.

a. Chillers

Chillers No. 1 – 4 are York, Turbomaster, sidewinder type 3,500-ton centrifugal chillers utilizing R134a. Each of the four chillers has a design capacity of 3,500 tons, but a lower operating capacity of 3,200 tons. Each machine has 2 HMI controllers for every unit. All the outboard compressor motor bearings have external fans blowing on them for additional cooling which indicates a potential problem with the chiller lube oil cooling. This may indicate an issue with a dirty lube oil circuit, clogged filters, or faulty pump.

There were minor oil leaks observed in and around the compressor and motor gearbox and bearings. All the isolation valves for the piping are located on the sub-floor below which may be difficult to access for maintenance. The machine, controls, and piping are all considered to be in Good-Fair condition. See Appendix for additional information.

Chiller Nos. 5 – 7 are York, MaxE, 3,500-ton, dual-compressor, centrifugal chillers. They each have 2 HMI control panels per unit. Chillers utilize R134a refrigerant and are equipped with a hot-gas bypass. All three are oil-lubricated by a dedicated pump and filter system.

The water isolation valves are all located on the sub floor level below the chillers. The chillers, controls, and piping are all considered to be in Good condition. It is recommended to replace all chiller condenser inlet and outlet valves in Phase 1to improve the efficiency of the chiller plant. See Appendix for additional information.

Photo 2.B.1: Chiller No. 1

Photo 2.B.2: Chiller No. 5

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b. Primary Chilled Water Pumps

The primary chilled water pumps are all installed on the sub-floor level of the chiller plant. All are horizontal, split-case type controlled by VFDs.

Each is mounted on a grouted steel frame bolted to a concrete inertia base.

The piping and pipe supports are in good condition with minor insulation and jacket repairs required. The insulation boxes are in poor condition and are allowing moisture to infiltrate causing condensation and eventual corrosion.

The pump isolation valves are dated, and verification of shutoff should be performed prior to any pump repairs.

The controls are in fair condition. The differential pressure switch for pump status appears to have been updated. The overall condition of the pumps and motors is Fair with the expectation that the pumps will be replaced within the next 5

– 10 years. See Appendix for additional information.

Photo 2.B.3: PCHWP No. 1

c. Secondary Chilled Water Pumps

The secondary chilled water pumps are in a dedicated space adjacent to the chiller plant.

They are all horizontal, split-case type with 600 HP motors controlled by VFDs. The piping and pipe supports are in good condition with all the pumps mounted on one large concrete block.

The insulation boxes are in poor condition and are allowing moisture to infiltrate and cause condensation which leads to corrosion.

The VFDs and pressure controls are antiquated and should be replaced when new pumps are installed. Due to the age of the equipment, replacement of the pumps and VFDs is recommended in the next 5 – 10 years based on an overall rating of Fair. See Appendix for additional information.

Photo 2.B.4: Secondary CHW Pumps

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d. Cooling Towers

Cooling Tower CT-305 consists of two field-erected, counter flow, induced draft type towers with four cells each. They are equipped with side inlet screens and ceramic fill. They share a common concrete basin but are not currently connected to Cooling Tower CT-317.

Cooling Tower CT-317 (2 cells) serves only Chiller No. 7 and the free-cooling H.X. The bird screens and louvers have been removed from the tower due to ice formation during the winter months. It is recommended to replace all cooling tower header valves when the associated towers are replaced. Overall, the towers are considered to be in Fair condition with 5 – 10 years of remaining useful life. See Appendix for

Photo 2.B.5: Cooling Tower CT-305

e. Condenser Water Pumps

The chilled water plant condenser water system consists of eight condenser water pumps. All pumps are vertical-turbine style. Pump Nos. 1 – 6 were manufactured in 2014, and each has a capacity of 10,500 gpm at 125’ TDH.

Pumps Nos. 7 and 8 can only be used with chiller No. 7. These pumps, along with CT-317 are also utilized for free cooling in the winter months.

A majority of the pumps witnessed in operation had a leaking mechanical seal. The pumps are in Fair-Poor condition, and there is currently a plan in place for replacement of four pumps (Nos. 2, 4, 5 and 6). The replacement of all pumps are recommended to be in the next 0 – 10 years. See Appendix for additional information.

Photo 2.B.6: CDWP Nos. 1 – 6

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f. Free-Cooling H. X. and Pumps

The free-cooling system consists of two plate and frame heat exchangers, two condenser water pumps, and CT-317. Each H.X. and pump are set on individual housekeeping pads. According to Operations staff, both heat changers provide a combined capacity of approximately 4,000 tons and can carry a majority of the winter load with one supplemental chiller. The H.X. operation is not automatic. All of the H.X.s isolation valves are manual requiring Operations to line-up equipment when conditions are favorable.

The insulation boxes on the pumps are in poor condition and should be replaced. It is recommended to eventually replace the H.X.

insulation with removable parts in order to service and clean the plates when appropriate.

The existing insulation is permanent. The overall rating of this equipment is Good-Fair (10 – 20 years). See Appendix for additional information.

Photo 2.B.7: Free Cooling H.X.

g. Condenser Water Sand Filters

The existing sand filtration equipment currently serves the condenser water system with four separate banks of filters as a sidestream system.

Skids 1 – 3 consist of 16 tanks serving the condenser water during the summer months.

Skid 4 has 3 tanks and is insulated since it is dedicated to the free-cooling system during the winter months.

All four skids are the same manufacturer and are all equipped with individual control panels and set on housekeeping pads. Plant Operations staff has indicated the need for chilled water sand filtration as well. It is recommended to install an additional sand filter bank for the chilled water system. Overall, the filtration system is rated as Fair. See Appendix for

Photo 2.B.8: CW Sand Filters

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h. Existing Chilled Water Temperature Differential

During a significant portion of the cooling periods, the secondary chilled water pump flow increases due to the differential pressure in the system. To equalize the flow across the decoupler, the plant personnel have to energize an additional primary chilled water pump and chiller. The campus load does not appear to increase resulting in a reduced temperature differential.

An ideal temperature differential is between 10°F and 20°F. A profile of the chilled water temperature differential as well as a duration curve (temperatures sorted from highest to lowest) for the past five years are presented in Figures 2.B.1 and 2.B.2.

Figure 2.B.1: Chilled Water Temperature Differential Profile (2018 – 2023)

Figure 2.B.2: Chilled Water Temperature Differential Duration Curve (2018 – 2023)

As presented above, the chilled water temperature differential is below 10°F for over 90% of the year.

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One potential cause for the low temperature differential is open cross connections in the system (potentially 3-way control valves at AHU’s) or chilled water bridge not operating properly. With the existing variable flow system, 2-way control valves should be installed at each of the AHU cooling coils and other terminal units. An open 3-way control valve in the system will result in the following conditions:

Chilled water flow bypassing the cooling coil

Lower chilled water return temperature

Reports false low load (low temperature differential)

Figure 2.B.3: Effect of 3-Way Control Valve with Variable Flow on Temperature Differential

Low temperature differential is usually the result of an issue within the buildings. As this POR analysis is limited to the CUP, it is recommended that the presence of 3-way control valves be investigated in the buildings and verify that the cross connection is closed or replaced with a 2-way valve. Any buildings with tertiary pumps and a building decoupler should also be verified for correct operation.

3) Steam Plant

The existing steam plant consists of six watertube steam boilers. Boiler Nos. 1 – 4 are rated at 44,000 PPH, and Boiler Nos. 5 and 6 are rated at 80,000 PPH each. Plant auxiliaries include two deaerators (DA) with three feedwater pumps, two condensate pumps with associated condensate return equipment, water softeners, fuel oil transfer pumps, chemical treatment system, and associated boiler blowdown equipment.

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a. Boilers

There are six existing boilers in the main Steam Plant, four of which have been in service for more than 60 years; i.e., Boiler No. 1 – 4 have been in service since 1961. The burners and combustion controls have been upgraded on these four boilers which has contributed to extending the service of the existing boilers beyond their typical useful life.

These boilers are rated as FAIR (5 – 10 years). A typical burner upgrade is indicated in Photo 2.B.9

According to Operations staff, Boiler Nos. 5 and 6 (newer) have given the plant more operational issues than Boiler Nos. 1 – 4 (older) such as tube failures and refractory repairs. These two boilers are rated as FAIR/POOR (0 – 10 years). It is recommended that all boiler controls, control panels, and HMIs be replaced when the respective boiler is replaced or upgraded. This includes the boiler booth and all boiler workstations and servers. Photo 2.B.10 indicates Boiler No. 5 control panel.

All six boilers are equipped with flue gas economizers for waste heat recovery and provide 150 psig steam to campus. At a minimum, it is recommended that Boilers 1 – 4 have internal waterside and fireside inspections to further determine the existing condition of each unit. This would include tube thickness, non-destructive testing (NDT), tube borescoping, and magnetic-particle or die-penetrant testing of the drums.

As an alternate, the boilers can be replaced within the next 10 years based on conversations with NIST personnel. See Appendix for additional information.

Photo 2.B.9: Blr. No. 1 Burner

Photo 2.B.10: Blr. No. 5 Panel

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b. Feedwater System

The existing feedwater system has two spray-tray type DA’s serving the boilers. Each DA is equipped with a full-size safety relief valve (SRV) vented through the roof. One DA was in operation at approximately 13.7 psig at 246°F which indicates proper saturated conditions for efficient deaeration of the feedwater. The feedwater piping, tank insulation, pipe insulation, unit controls, and overall condition of the DA is GOOD/FAIR based on age and visual survey.

Both DA tanks were rebuilt in 2022 with internals replaced and both shells tested and recertified. It is recommended that a drip-pan elbow assembly be installed on each of the relief valves.

Three boiler feedwater pumps (BFWPs) supply feedwater to the boilers. All three pumps are horizontal, split-case, centrifugal type equipped with motor starters which are in FAIR/POOR condition. Pump No. 3 was online at 20 psig suction pressure with no visible or audible signs of excessive vibration or uncharacteristic noise. All three pumps have oil-lubricated bearings and integral H.X.s for mechanical seal cooling. All couplings and coupling-guards are in GOOD condition. Overall, the feedwater pumps are considered to be in FAIR/POOR condition and are recommended for full replacement in the next 0 – 10 years. See Appendix for additional information.

Photo 2.B.11: DA No. 2

Photo 2.B.12: BFWP No. 3

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c. Condensate Return System

The condensate return system consists of two condensate pumps and one condensate receiver.

The two condensate pumps take suction from the main receiver and pump to the deaerators. The pumps are end-suction, direct-coupled, centrifugal type on starters as indicated in Photo 2.B.13 (Pump No. 9). Pump No. 10 was on-line at 115 psig discharge pressure which is appropriate for this application with no signs of excessive noise or vibration.

Condensate piping is not completely insulated, and insulation is damaged and falling off. It is recommended that both condensate pumps be replaced as they are considered to be in Fair-Poor condition. It is also recommended that the condensate receiver (FAIR) be replaced due to age.

See Appendix for additional information.

Photo 2.B.13: CDWP No. 9

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d. Boiler Blowdown Systems

The existing bottom blowoff (BBO) tank handles the bottom blowdown for all six boilers and Heat Recovery Steam Generator (HRSG) in the Steam Plant and Cogeneration Plant. The flash tank properly vents thru the roof to atmosphere. The tank and piping insulation are in Fair-Poor condition. Based on age, visual inspection, capacity, and availability of spare parts, the unit should be replaced in its entirety in the next 0 – 10 years. We recommend replacing all BBO piping from the boiler mud drums up to the BBO tank when this equipment is replaced.

The continuous blowdown (CBD) H.X and tank are in FAIR/POOR condition and should be replaced and are indicated in Photo 2.B.14. It is properly piped to preheat the soft water and to capture flash steam back into the low-pressure steam system.

Associated piping is not well supported and temperature sensing wires are loose. It is recommended that NIST replace all CBD piping from the boiler steam drums up to the CBD assembly when this equipment is replaced. It is also recommended to replace the blowoff piping trench covering and repairing the floor and trench.

See Appendix for additional information.

Photo 2.B.14: CBD Tank

e. Water Softeners and Polisher

The existing water softening system consists of four softener vessels equipped with multi-port flow control valves. The softeners are sized for 100% make-up water flow. The soft water piping is a combination of copper and PVC in GOOD/FAIR condition. Piping insulation is missing in some areas, damaged in others, and not sealed at joints for a proper vapor barrier. Two of the softeners were on-line at approximately 70 psig supply pressure, and two units were in standby.

All softening equipment is considered to be in Good-Fair condition as shown in Photo 2.B.15.

The existing condensate polisher is a sidestream application that is currently out of service due to excessive vibration during operation. It is recommended to replace this unit (FAIR/POOR) with a new system sized for 100% make-up water flow. See Appendix for additional information.

Photo 2.B.15: Water Softeners

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f. Chemical Treatment System

Photo 2.B.16 indicates the existing chemical feed (CF) lineup for the Steam Plant without proper secondary containment. The CF piping is in FAIR condition utilizing a combination of PVC pipe, plastic tubing, stainless steel (S.S.) tubing, and carbon steel piping. The tanks, pumps, and controls are all in FAIR condition. A more in-depth review of the chemical treatment logs and inspection of internal water sides of equipment would need to be completed to fully understand the effectiveness of the existing chemical treatment program.

It is recommended to redesign the CF system storage area that includes proper secondary containment and all new controls in order to closely control the delivery of chemicals into the system and to automate the controls to the fullest extent possible. See Appendix for additional information.

Photo 2.B.16: Steam Plant Chem. Treat.

g. Fuel Oil System

The existing fuel oil (FO) system consists of two positive-displacement type transfer pumps that take suction from No. 2 FO underground storage tanks.

The system serves the six gas/ oil boilers in the main Steam Plant. The condition of the underground tanks is unknown at this time. The pump skids are mounted on housekeeping pads, but the skids are not grouted.

If the pumps are to remain in service, it is recommended to grout the bases. Pump over-pressure protection is in place via safety relief valves on the discharge header relieving back to the FO return. The pumping station is located within a secondary containment basin pit. The overall condition of the pumping station is FAIR/POOR (0 – 10 years). See Appendix for

Photo 2.B.17: Fuel Oil Pumps

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h. Compressed Air System

The existing compressed air system is divided into two separate systems: plant air and campus air.

Campus air is not part of the scope of work for this condition assessment, therefore, only the plant air compressor will be discussed in this section.

The existing plant air compressor is a 4-cylinder, belt-driven, reciprocating compressor with integral receiver and filter-dryer…