20250418_-_IFB_Design_Narrative_-_CVG_Industrial_Rehabilitation_and_Efficiency_Program.pdf

CVG Industrial Rehabilitation and Efficiency Program Cincinnati Northern Kentucky International Airport

3087 Terminal Dr, Hebron, KY 41048

IFB Design Narrative April 18, 2025

Prepared By:

Kohrs Lonnemann Heil Engineers 1538 Alexandria Pike Ft. Thomas, KY 41075

FOR REFERENCE ONLY

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Table of Contents

1. Executive Summary

2. Design Standards

3. List of Clarification of Standards

4. Amendments to Scope of Work

5. Demolition & Asbestos Abatement

6. Projects

Boiler Existing Conditions Design Consideration Recommendation

Towers Existing Conditions Design Considerations Recommendations

Generators Existing Conditions Design Considerations Recommendation

Facility roadmap considersations HVAC Hot Water System HVAC Controls

Attachments

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1. Executive Summary The scope of the project is to provide engineering design services for KCAB’s Industrial HVAC Rehabilitation & Efficiency Program Design.

• Replacement of 5 Terminal cooling towers

• Replacement of 8 cooling towers associated with Concourse B HVAC system

• Replacement of 3 boilers in the Terminal and 5 boilers in Concourse B with updated condensing boiler technology. 4 boilers in terminal and 6 boilers in Concourse B.

• Integration of BAS controls and elimination of pneumatic controls where required in the

Terminal, and Concourse B

• Replacement of 1 generator in Concourse A

2. Design Standards This work is governed by the Design Standards which were in effect at the time of the award of the contract in October 2024.

• 2018 Kentucky Building Code (IBC 2015)

• 2018 Kentucky Fire Code (NFPA 1, IFC 2018)

• 2015 Kentucky Mechanical Code (IMC 2015)

• 2012 Commercial Energy Conservation Code of Kentucky (IECC 2012)

• 2017 Kentucky Electrical Code (NFPA 70, 2017)

• American National Standards Institute (ANSI)

• National Electric Code (NEC)

• National Electrical Safety Code (NESC)

• National Fire Protection Association (NFPA) Standards including, but not limited to, NFPA 101 - Life Safety Code

• National Electrical Manufacturers Association (NEMA)

• Underwriters Laboratory (UL)

• Uniform Building Code (UBC)

• Uniform Plumbing Code (UPC)

• American Society of Heating, Refrigeration and Air-Conditioning Engineers (ASHRAE) o ASHRAE 62 o ASHRAE 90.1

• Illuminating Engineering Society of North America (IESNA)

• American Institute of Architects (AIA) Masterspec

• Air-Conditioning and Refrigeration Institute (ARI)

• Occupational Safety and Health Administration (OSHA) regulations

3. List of Clarification of Standards CVG Design Criteria Manual – 07.29.24 Version 1.1

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4. Amendments to Scope of Work As of the issuance of this narrative there have been (1) modifications to the scope of work and described in Exhibit D.

5. Demolition & Asbestos Abatement Asbestos Containing Material (ACM) impacting this project has not been identified at the point in time of this report. CVG does not have any current records for any inspections or past abatement within the project scope of work area. Should this project encounter ACM material the owner (CVG) will be responsible for containing and abatement.

6. Projects

BOILER

Existing Conditions The existing heating hot water systems in the Ticketing Building and Concourse B consist of high temperature, gas fired boilers and centrifugal hot water pumps. The local boiler and hot water controls are a hybrid of pneumatic and direct digital controls (DDC). The current system is a variable speed primary pumping arrangement serving VAV terminal units and air handlers throughout the campus. There are multiple pumps in each plant but no redundancy.

The current design hot water supply temperature is 200ºF and is currently operating at 180 ºF.

Operators report that the boiler systems cannot meet the heating demand on the very coldest days of the year. Current load information is being gathered from documentation, measurements, and a review of historical trend data from the building automation system (BAS).

The current boiler room area is served by fluorescent lighting that is aged and in need of repair/replacement.

The main terminal flue has evidence of rot and has had leakage issues in the past

Design Consideration Goals for this portion of the project are an increase in energy efficiency, improvement in maintainability, reliability/redundancy, and higher performance.

New hot water equipment also needs to be compatible with the existing HVAC systems and new systems being designed and installed under other portions of this project. The primary compatibility concern is hot water supply temperature. Newer, more efficient equipment supplies water at a lower temperature than older designs.

Boiler sizing will be based on a few factors. Existing BAS trend data will be reviewed along with new equipment selected by the current CVG project to establish a new plant size with redundancy.

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Recommendation The primary means for achieving higher performance and higher efficiency is through the installation of new, condensing-type hot water boilers. These boilers operate at lower water temperatures for increased thermal efficiency. Condensing boilers can typically supply higher water temperatures as well, but at a reduced efficiency. Each of the existing boilers will be replaced with a condensing-type. An additional boiler, of equal size, will be provided for N+1 redundancy in each plant.

Other equipment that will need replacement to support new boilers are the flue system and the condensate drainage system. The boiler flue must be properly sized for the condensing boiler’s output and constructed of stainless steel as the boiler exhaust is corrosive. The new flue systems will also include draft fans to ensure a strong draft under low fire operation.

Condensing boilers also generate a stream of condensate water that must be drained. This condensate is typically too hot and corrosive to be directly routed to a floor drain. A condensate treatment system will be needed.

New variable speed, high efficiency hot water pumps will also be installed to replace the existing pumps. An additional pump of equal size will be provided for N+1 redundancy. New variable frequency drives (VFD) will be installed, utilizing existing electrical feeds. A new feed and circuit breaker will be provided from existing distribution equipment in the boiler room for the new redundant equipment. Along with the pumps, new housekeeping pads, hydronic specialties and piping will be required. New compression tanks and makeup water systems will be required.

The combustion air damper systems will be replaced.

Terminal

• Replace existing (3) 5520 MBH boilers with (4) 5520 MBH boilers o Condensing type, gas fired hot water boilers o Include a new controller for each boiler o Include condensate neutralization system o See attached product data for basis of design

• Replace (2) 25hp base mounted hot water pumps with (3) 25hp base mounted hot water pumps o Remove piping and all accessories to the boundary of the room o Include new VFD and controls for each pump o Includes replacement of all hydronic specialties & controls o Requires partial hot water system drain down o See attached product data for basis of design

• Replace all hot water piping inside the boiler room boundary

• Include piping provisions for future pump, future boiler, and temporary boiler connections

• Install new boiler condensate drain piping to floor drains

• Replace existing boiler and pump housekeeping pads

• Replace complete boiler flue system.

• Replace existing combustion air inlet dampers with (1) set of dampers per boiler

• Replace gas piping inside the mechanical room, including all accessories, valves, etc

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• Replace makeup water connection and BFP station inside the boiler room

• Replace lighting with new LED fixtures

Concourse B

• Replace existing (5) 6695 MBH boilers with (6) 6695 MBH boilers o Condensing type, gas fired hot water boilers o Include a new controller for each boiler o Include condensate neutralization system o See attached product data for basis of design

• Replace (2) 30 hp base mounted hot water pumps with (3) 30 hp base mounted hot water pumps o Remove piping and all accessories to the boundary of the room o Include new VFD and controls for each pump o Includes replacement of all hydronic specialties & controls o Requires partial hot water system drain down o See attached product data for basis of design

• Replace all hot water piping inside the boiler room boundary

• Include piping provisions for future pump, future boiler, and temporary boiler connections

• Install new boiler condensate drain piping to floor drains

• Replace existing boiler and pump housekeeping pads

• Replace complete boiler flue system

• Replace gas piping inside the mechanical room, including all accessories, valves, etc

• Replace makeup water connection and BFP station inside the boiler room

• Replace lighting with new LED fixtures

TOWERS

Existing Conditions The existing condenser water systems consists of 5 crossflow cooling towers and 3 condenser water pumps in the Terminal Building, and 8 crossflow cooling towers and 3 condenser water pumps in Concourse B. The cooling towers were designed for 95°F EWT, 85°F LWT, 78°F WB.

The original condenser water plants included waterside economizer for each system. In addition to leaking issues, the operators reported that the heat exchangers were undersized and could not keep up with the building’s cooling demand, resulting in required chiller operation during the winter.

Service records indicate that the cooling tower casing panels and both hot and cold water basins are corroded and are in need of replacement. Additionally, the basin nozzles were reported to be loose and clogged due to basin conditions and debris, and the heat transfer fill has become brittle due to age.

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Design Considerations The goal for this portion of the project is to restore the reliability and performance of the condenser water system. The new condenser water system also needs to include appropriately sized heat exchangers to restore waterside economizer operation for the air handling systems to be energy efficient and code compliant.

Recommendations Terminal

- Replace existing (5) 765-ton cooling towers with (5) 765-ton cooling towers o Galvanized cooling tower, PVC fill, stainless steel basin, electric basin heaters, side stream separators, basin sweepers, external ladders with safety cages, external platform near distribution system, handrails, internal platforms, and motor davits.

- Replace all condenser water piping, control and manual valves, heat trace, and sensors

- Replace existing cooling tower support dunnage and foundations

- Replace condenser water piping to 20’ inside the building and repair underground pipe penetration location to resolve leaking issues.

- Replace and re-slope concreate apron adjacent to building (approx. 750 SF)

- Re-slope and regrade cooling tower yard to existing catch basin (approx. 3,500 SF)

- Remove (2) existing cooling tower drain down drains and replace, re-pipe to new grading

- Replace (3) Condenser water pumps, replace starters with VFDs o Remove piping and all accessories to and including the pump isolation valves o Includes replacement of all valves, strainers, and gauges o Requires condenser water system drain down

- Replace MCDTHBA-E Motor Control Panel

- Provide new plate and frame heat exchanger in location of the removed heat exchanger and extend condenser and chilled water piping to previous heat exchanger piping connection location. Provide all new shut off valves, strainers, and gauges.

o Requires chilled water drain down and refill. This work will be isolated to the chiller room.

Concourse B

- Replace existing (8) 500 ton cooling towers with (5) 500 ton cooling towers o Galvanized cooling tower, PVC fill, stainless steel basin, electric basin heaters, side stream separators, basin sweepers, external ladders with safety cages, external platform near distribution system, handrails, internal platforms, and motor davits.

o This reduction in cooling tower capacity is to match the reduction in chiller capacity over the years.

- Replace all condenser water piping, control and manual valves, heat trace, and sensors o New piping supports attached to roof structural system and roof flashing

- Existing cooling tower support dunnage to remain.

- Replace condenser water piping to just before roof penetration

- Replace (3) Condenser water pumps, replace starters with VFDs

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o Remove piping and all accessories to and including the pump isolation valves o Includes replacement of all valves, strainers, and gauges o Requires condenser water system drain down

- Replace MCECH##-H Motor Control Panel o Located on Concourse B basement with feeders running to the roof.

- Provide new plate and frame heat exchanger on existing Chiller #2 empty pad and extend condenser and chilled water piping to previous heat exchanger piping connection location. Provide all new valves, strainers, and gauges.

o Requires chilled water drain down and refill isolated to the chiller room.

GENERATORS

Existing Conditions In Concourse A room A103 there is a 500kW/625kVA generator EG-17 that feeds 1600A switchboard EDSDCH1A at 480/277V, 3-phase. From this switchboard, (2) ATS are installed in the concourse that serve downstream panelboards. These panelboards have the same mix of NEC 700 and 702 loads connected to them. All equipment surveyed are base their useful life and due for replacement.

Design Considerations KCAB has requested replacement of the generators, transfer switches, and paralleling gear mentioned in the previous section. The following design considerations form the basis for their replacement:

• All the equipment is past its useful life making it difficult to maintain and find parts for.

This will require a total replacement, without reuse of any parts or accessories. This will include removal of associated components like annunciators, conduit, and conductors.

• Concourse A systems serve a mix of NEC 700 emergency/life-safety and NEC 702 optional standby loads. This was common practice for buildings of this age but per the NEC version 2017, the currently adopted version in Kentucky, section 700.10(B) states this is not permitted. We will evaluate this with the local AHJ, but it is likely that the creation of a separate NEC 700 branch of power will be required as a part of this project.

This narrative assumes this is the case and outlines the scope of work required in the following sections.

• The current sequence of operations for all generators is sufficient and will not require modification.

• The current fueling systems for all generators are sufficient and will not require modification.

• The ratings of all existing equipment and feeders are sufficient and will not require upsizing.

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Recommendation Concourse A KLH recommends a one for one swap of generator EG-17 but with the addition of (3) integral circuit breakers. (2) to feed the existing ATS and (1) to feed a new, dedicated emergency ATS.

While is replacement occurs, emergency power will not be available in the concourse; however, no outages should be experienced unless a normal power failure also occurs.

KLH recommends a one for one replacement of both ATS with new 480/277V, 3-phase, 4-wire, 4-pole versions. The existing ratings and locations are listed below. An outage will be required for everything downstream of each ATS during replacement.

• ATAGHTB - 250A

• ATDCH1A - 400A

Also, unless approval from the AHJ is given to exclude the creation of a separate NEC 700 emergency branch, we recommend a new 200A ATS, matching the specs of the replaced ATS above, be installed with feeds from the new generator and a normal source to be determined.

This transfer switch will feed a 200A fused panelboard (equal to Eaton QSCP) that will distribute power to new, dedicated, 480/277V, 3-phase, 4-wire, fused panelboards (equal to Eaton QSCP). These panelboards are planned for installation in the following rooms, and the quantity of emergency circuits indicated will be moved from the existing emergency panels to the new.

An outage will be required on each circuit while transitioned:

• Electrical Vault D-4 A116: (6) single pole circuits

• Electrical A103: (1) single pole circuit

• Electrical B117: (9) single pole circuits, (1) 3 pole circuits

• Elec A101: (16) single pole circuits

• Elec B104: (?) single pole circuits (unverified)

FACILITY ROADMAP CONSIDERSATIONS

HVAC Hot Water System The new boilers will be fully compatible with the existing HVAC equipment that was originally designed for higher temperature supply water. One of the primary means for maximizing boiler plant efficiency is through supply temperature reset schedules. This reduces the temperature of the hot water during low load operation. Boiler plants typically operate far below maximum capacity for the majority of the heating season. Only the coldest days of the year require full production of hot water. The supply temperature will be reset based on system load. As more hot water valves in the system open, the supply temperature will be raised. As spaces become satisfied and control valves start to close, the supply temperature will be lowered. This ensures that the system is operating at as low a temperature (and as high efficiency) as possible at all times.

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HVAC Controls The current control system at the airport is a legacy Honeywell pneumatic system that has been operational for over 30 years. The system comprises pneumatic actuators, analog controllers, and Honeywell Excel or Delta series DDC panels. These panels communicate with limited BAS functionality, providing rudimentary scheduling, setpoint adjustments, and alarm monitoring capabilities.

The pneumatic system serves as the primary control medium for valves and dampers in the HVAC infrastructure, including boilers, cooling towers, and air handling units. Over time, mechanical wear, limited availability of replacement parts, and inefficient energy management have degraded system reliability and operational performance. Additionally, the lack of integration with modern digital communication protocols restricts the system's ability to interface with advanced BAS platforms.

The initial phase of the upgrade focuses on transitioning key components to modern digital controls while maintaining compatibility with the existing infrastructure. The scope includes Boiler system upgrades, Cooling tower upgrades, select AHU upgrades, Generator monitoring, and replacement of pneumatic control valves and actuators to electric.

The remaining HVAC system components will require phased upgrades to fully transition the airport to modern, energy-efficient, and scalable control system. Key future tasks include:

replace all remaining AHU controls, replace existing chiller primary and secondary pumps, and replace any remaining zone control valves.

Expanding the BAS backbone to support additional controls and sensors will require upgrading wiring, network switches, and new control panels.

Attachments Exhibit A - Assessment Data_Open Space Field Notes Exhibit B - Assessment Data_Envision Field Data Sheets Exhibit C – 20241024_Preliminary Scope Redlines Exhibit D - 20240927 Attachment A - Current Equipment Listing Exhibit E - Mechanical HWS from Existing Drawings 1 – Terminal Exhibit F - Mechanical HWS from Existing Drawings 4 - Concourse B

Attachments