S02 Final BOD Chilled Water Study.pdf

Chilled Water Investigation

Final Bid Documents Submission Retro-Commissioning Mechanical Corrections

Contract: 36C24418C0071

Submitted to:

U.S. Department of Veterans Affairs

Lebanon VA Medical Center Attn: Brian Pedersen

1700 South Lincoln Avenue Lebanon, PA 17042

Submitted by:

Alares Engineering 248 Copeland Street Quincy, MA 02169

November 2019

Lebanon VA Medical Center

Achieving swift results

Table of Contents

1.0 Executive Summary

2.0 Chilled Water System Background

3.0 Model Description

Assumptions and Inputs

4.0 Building Overviews

Building 10 – Chiller Plant

Building 1 – Main Hospital

Building 2 – Admin

Building 6 – Warehouse

Building 7 – Laundry

Building 17 – Ambulatory Care

Building 18 – Outpatient

Building 19 – Police/Admin

Building 22 – Education

Ice Storage Plant

Building 23 – Admin

Building 24 – YMCA

Building 101 – Hospital

Building 102 – Rehab

Building 104 – Hospital

Building 106 – Chapel

Building 136 – IT

5.0 Model Results

Chilled Water Primary Pumps

5.1.1. Chilled Water Primary Pump Capacity

5.1.2. Chilled Water Primary Pump Control

Chilled Water Secondary Flow

Chilled Water Piping Size

Chiller Plant Capacity

Cooling Tower Capacity

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Relocate Differential Pressure Sensors

Convert OR Air-Cooled Chiller to the Backup Chiller for Building 101

Replace Chilled Water Flow Meters

Building 106 Flow Issue

Building Piping Issues

6.0 Conclusions

List of Tables

Table 1: Chiller Plant – Equipment Overview

Table 2: Buildings and Equipment – Model Summary

Table 3: Building 1 Chilled Water Risers

Table 4: Building 1 – AHU Overview

Table 5: Building 1 – Pump Overview

Table 6: Building 17 – AHU Overview

Table 7: Building 17 – Pump Overview

Table 8: Building 18 – AHU Overview

Table 9: Building 18 – Pump Overview

Table 10: Building 19 – AHU Overview

Table 11: Building 19 – Pump Overview

Table 12: Building 22 – AHU Overview

Table 13: Building 22 – Pump Overview

Table 14: Ice Storage Plant – Chiller Overview

Table 15: Ice Storage Plant – Pump Overview

Table 16: Building 23 – AHU Overview

Table 17: Building 23 – Pump Overview

Table 18: Building 101 – AHU Overview

Table 19: Building 102 – AHU Overview

Table 20: Building 104 – AHU Overview

Table 21: Building 104 – Pump Overview

Table 22: Building 106 – AHU Overview

Table 23: Building 136 – AHU Overview

Table 24: Building 136 – Pump Overview

Table 25: Piping Identified for Possible Re-Sizing

Table 26: Differential Pressure Sensors Identified for Possible Relocation

Table 27: Flow Meters Proposed for Replacement

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List of Figures

Figure 1: Site Map

Figure 2: Building 10 – Satellite Image

Figure 3: Building 10 – Model Overview

Figure 4: Building 1 – Satellite Image

Figure 5: Building 2 – Satellite Image

Figure 6: Building 6 – Satellite Image

Figure 7: Building 7 – Satellite Image

Figure 8: Building 7 – CHW Piping to Fan Coil Unit

Figure 9: Building 17 – Satellite Image

Figure 10: Building 18 – Satellite Image

Figure 11: Building 18 – Model Overview

Figure 12: Building 19 – Satellite Image

Figure 13: Building 19 – Model Overview

Figure 14: Building 22 – Satellite Image

Figure 15: Building 22 – Model Overview

Figure 16: Ice Plant – Satellite Image

Figure 17: Ice Plant Storage – Model Overview

Figure 18: Building 23 – Satellite Image

Figure 19: Building 23 – Model Overview

Figure 20: Building 24 – Satellite Image

Figure 21: Building 24 – Model Overview

Figure 22: Building 101 – Satellite Image

Figure 23: Building 101 – Model Overview

Figure 24: Building 102 – Satellite Image

Figure 25: Chilled Water Piping from Building 1 to Building 102

Figure 26: Building 102 – Model Overview

Figure 27: Building 104 – Satellite Image

Figure 28: Building 104 – Model Overview

Figure 29: Building 106 – Satellite Image

Figure 30: Building 106 – Model Overview

Figure 31: Building 136 – Satellite Image

Figure 32: Building 136 – Model Overview

Figure 33: Building 18 – Head Loss Path

Figure 34: OR Air-Cooled Chiller

Figure 35: Typical Piping Arrangement for Primary-Secondary Loop Transitions

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Appendices

Appendix A – Chilled Water Model Overview Appendix B – Drawings Used to Create Model Appendix C – Individual Building Model Overviews Appendix D – HVAC Site Utility Piping Plan (05/14/2012) Appendix E – Location of recommended resized piping

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1.0 Executive Summary

Alares Engineering (Alares) was retained by the Department of Veterans Affairs (VA) for designing

Retro-Commissioning (RCx) Mechanical Corrections at the Lebanon VA Medical Center

(LVAMC). Services include site investigation, design development, preliminary drawings, construction drawings, specifications, cost estimates, and construction period services.

During review of the 35% design submission for the project, the VA noted issues with the chilled water system. The VA requested Alares to identify potential chilled water upgrades to repair problematic areas with the chilled water system which also could provide substantial energy-efficiency improvements. Further, this study would include drawings of the chilled water system which can aid the maintenance staff and would be beneficial for any future upgrades at the campus.

One of the goals of the study is to optimize the campus chilled water system by gathering system data and inputting the data into a modelling software program. The software program calculates the optimum flows and loads of the chilled water system. The model results were compared to the existing data to identify problem areas and provide future upgrade projects to repair and improve the system.

To collect the data, Alares performed numerous site visits to collect data of the chilled water system and its components, measure pipe runs, confirm flow meter locations, confirm equipment make/model information, obtain other equipment parameters, and verify BAS and trend data where possible.

Using the collected data, Alares developed a chilled water model of the campus using the HVAC

Solution – Professional software. The model results are included in Appendix A. The chilled water modeling study identified the following:

• The primary loop pumps are undersized at maximum design conditions.

• Secondary loop pumps are undersized at maximum design conditions.

• Several pipes on the secondary loop are undersized.

• The chiller plant is currently at capacity.

• The cooling towers are undersized

• Differential pressure sensor locations are not ideal.

• Flow meters require replacement.

• Building 101 air-cooled chiller should be backup for the operating suite.

• Building 106 should be separated from the primary loop.

• Building primary-secondary piping has issue.

• Test and Balance data gaps exist throughout the secondary loop.

Based on these findings, the recommendations are as follows.

1. Conduct a detailed test and balance on the primary and secondary loop to confirm study findings.

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2. Resize/replace the primary loop pumps

3. Resize/replace secondary loop pumps

4. Replace undersized piping

5. Upsize the cooling towers

6. Add pressure sensors.

7. Replace flow meters

8. Change the OR chillers as back-up

9. Add secondary pumps to Building 106

10. Building Primary-Secondary loop bypass modification

11. Add circuit setters to branch piping in Building 1.

TAB should be performed on the existing secondary chilled water system before implementing the other recommended measures. TAB will provide a much greater understanding of the pumping capacity and whether the current flow rates are adequate to satisfy cooling demands on design cooling days. The TAB results will confirm model results and dictate the location of the pressure sensors and flow meters.

The facility already has plans in place to replace its existing chillers and cooling towers. Part of this upgrade project will include balancing of the primary chilled water loop. Paired with the results of the secondary chilled water TAB work, the facility will have a full picture of how its entire chilled water system is performing and can use this information to design and implement the other recommendations from this study to provide the facility a balanced and efficient chilled water system.

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2.0 Chilled Water System Background

The Lebanon Veterans Affairs Medical Center (VAMC), located in South Lebanon Township, has been providing care to veterans for more than 70 years. There are roughly 50 buildings on campus, with services including Ambulatory Surgery/Surgical Procedure Clinic, Audiology, Community Residential Care, Dental, Hospital Based Primary Care, Intensive Care – Medical and

Surgical, Nuclear Medicine, Nursing Home Care, Physical Medicine and Rehabilitation, Primary

Care, Recreation, Specialty Care/Clinics, Substance Abuse Treatment, Vocational Rehabilitation, Volunteer Program, and Women’s Health.

Figure 1: Site Map

The focus of this study is the chilled water distribution system. The buildings included in this investigation are 1, 2, 6, 7, 10, 17, 18, 19, 22, 23, 24, 101, 102, 104, 106, 136, and the ice storage plant.

The main chiller plant is located in Building 10. It consists of two water-cooled chillers (CH-1 is

960 tons and CH-2 is 1,020 tons), and three variable-speed fan cooling towers that provide chilled water across the campus.

The primary chilled water loop contains three 100 horsepower primary pumps located in Building

10, with most buildings having a secondary pumping system located in the building’s respective basement. There are several air-cooled chillers located around the campus which provide cooling to individual air handling units. For instance, there is an air-cooled chiller on the 2nd floor roof of

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Building 1 which supplies chilled water to the Building 101 air handling units. Campus chilled water acts as backup in this scenario.

The condenser water loop consists of three 75 horsepower condenser water pumps located beside the primary chilled water pumps in the main chiller plant.

Building 2 has its own separate chilled water system and only uses campus chilled water as a backup to the air handling unit that conditions the data center. Additional plant details are provided in the table below.

Table 1: Chiller Plant – Equipment Overview

Equipment ID Size Year of Installation

Chillers

10-CH-1 910 tons 1997

10-CH-2 1,020 tons 2007

1-ACCH-1 150 tons 2012

Cooling Towers

10-CT-1 50 HP 1997

10-CT-2 50 HP 1997

10-CT-3 50 HP 1997

Chilled Water Pumps

10-CHWP-1 100 HP 2004

10-CHWP-2 100 HP 2004

10-CHWP-3 100 HP 2004

Condenser Water Pumps

10-CWP-4 75 HP N/A

10-CWP-5 75 HP N/A

10-CWP-6 75 HP N/A

There are completed designs in place to replace both the chillers and cooling towers, and these projects will be going into construction within the next year. The cooling towers project will involve demolishing the existing towers on the roof and installing new towers outside of the plant at the northeast corner of the building. The new chiller project will include installing two new centrifugal chillers—rated at 950 tons each—and replacement of the existing chilled water pumps.

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3.0 Model Description

Alares utilized HVAC Solution – Professional1 to create the chilled water model of the campus system. This software “allows the user to drag-and-drop super-intelligent objects to design air systems including both air handlers and rooftops. It also provides tools to build hydronic, steam and control systems. The software includes all the necessary piping and ductwork components to model most systems.”

There was a total of 16 buildings and the ice storage plant included in the model. A summary of the buildings and the equipment included in the model can be found in the table below:

Table 2: Buildings and Equipment – Model Summary

Building Equipment Calculated in Model

Note

(12) AHUs

(2) CHWPs Grouped FCUs

(2) Flow meters

Yes Fan coil units are grouped and displayed as one FCU per floor/area within the model.

(5) AHUs

(2) CHWPs

No CHW from main plant is only available to be used by the 30-ton system in the event of failure.

6 (1) AHU No No information on unit

7 (1) FCU No Unit load is negligible.

(2) Chillers

(3) CHWPs

(3) Cooling towers

(3) CWPs

(6) Flow meters

Yes

(9) AHUs

(2) CHWPs Grouped FCUs

(2) Flow meters

Yes Fan coil units are grouped and displayed as one FCU per floor/area within the model.

(5) AHUs

(2) CHWPs

(2) Flow meters

Yes

(4) AHUs

(2) CHWPs

Yes

(3) AHUs

(2) CHWPs

(2) Flow meters

Yes

(4) AHUs

(2) CHWPs

(2) Flow meters

Yes Assumed 100,000 BTUH and a 10 ˚F ΔT for all four units.

1 “HVAC Solution – Professional.” HVAC Solution, Inc. https://www.hvacsolution.com/products.php?m=detail&id=3 https://www.hvacsolution.com/products.php?m=detail&id=3

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Building Equipment Calculated in Model

Note

(2) AHUs

(2) CHWPs

(4) FCUs

Yes One AHU, FCUs, and CHWPs are future equipment.

101 (5) AHUs Yes The two new units were not added to the model as they are still under construction.

102 (1) AHU Yes

104 (9) AHUs Yes Two units are tied but shown as future roof loads. These are not calculated in the model.

106 (1) AHU Yes

(1) AHU

(2) CHWPs

Yes

Ice Storage

(16) 3-tank storage systems

(3) Air-cooled chillers

(6) CHWPs

(1) Heat exchanger

No Ice storage plant is for illustration within the model.

An overview of the entire campus can be found in Appendix A.

Assumptions and Inputs

Information used in the modeling system was gathered from the site visits and through RFIs.

Alares performed numerous site visits to obtain design drawings, as well as to verify and document the as-built condition of the facility. AHU equipment information was found in design drawings and the January 4, 2006 TAB report prepared by Valley Testing and Balancing, Inc.

The facility chilled water starts with the chiller plant and ends at the cooling coils of the air handling or fan coil units. The primary inputs to the model are the BTU/hr ratings and ΔT for each air handling unit chilled water coil. The software calculates the gallons per minute (GPM) needed at each coil and determines the required pump flow and chiller capacity.

The secondary inputs to the model are pipe diameter, pipe length, and pressure drop through the chillers and coils. Based on all inputs, the software calculates the required head pressure for each pump.

Lastly, the major contributors to head loss (air separators, control valves, strainers, etc.) were added to the model where identified in the field and where applicable.

The following assumptions have been made:

• All Buildings

Lebanon VA Medical Center o Fan coil units were grouped by floor and represented as a singular coil. Combined

BTUH value was used, and the largest pipe diameter on that pipeline was inputted for size.

o If sizing information was not available for newer fan coil units, they were not represented in the model.

o The air handling unit coils were each modeled with an isolation valve and a strainer on the supply line, and a control valve on the return line. The isolation valves and strainers were not all verified.

o Not all the design values for the BTUH of the air handling unit coils were obtained.

In addition, there were some conflicting data from multiple sources on some occasions. Ultimately, Alares used the source that seemed to be the most recent and/or correct and made engineering estimates where information was not available.

o In-line circulating pumps were not inputted into the model as they do not directly affect the outputs of the model.

o For clarity in the model, Alares did not include all the valves, strainers, air separators, and/or other contributors to pressure drop near the chillers and pumps so they are not included in the calculated pump heads.

o Some buried piping sizes were assumed due to inaccessibility. An example of this is the piping that runs from the pipe vault towards buildings 19/22/24 and 18/106, where Alares used the model recommended pipe diameter of 8”.

o Default pressure drops were used for all components throughout the chilled water system.

o The only testing, adjusting, and balancing (TAB) reports are as follows:

▪ Test, Adjust and Balance Report, January 2006: main chiller plant, chilled water flows at eight buildings, and chilled water pumps at seven buildings

▪ Radiology Phase I TAB Report, September 2014

• Building 1 o See previous assumption related to grouping/representing fan coil units. This applies to the Ground, 1st, 2nd, 3rd, 4th, and 5th floors.

o The air-cooled chiller on the 2nd floor roof is not in operation.

• Building 2 o Alares assumed the campus chilled water system is only available to be used by the 30-ton chiller in the event of failure as backup.

• Building 6 o Limited information was available for the chilled water devices in this building. Based on some of the conflicting information for this building, it was assumed that this load is negligible to the overall model.

• Building 7 o Chilled water is provided to a sole fan coil unit. It was assumed that this load is negligible to the overall model.

• Building 10

Lebanon VA Medical Center o Chilled Water Plant Operation

▪ Design information on the existing chillers was very limited. The design drawings for the latest planned upgrades were used for sizing, along with the proposed sequences.

▪ It was not possible to integrate the ice storage system into the model.

o For clarity in the model, Alares did not include all valves, strainers, air separators, and/or other contributors to the pressure drop near the chillers and pumps, so they are not included in the calculated pump heads.

o While surveying the chiller plant equipment, Alares did not see valves V-4, V-5, or

V-6 in the field.

o The flow meters were not labeled in the field. As a result, the identifiers shown on the model are Alares’ identifiers.

• Building 17 o No information was available for the two rooftop units on the 1st floor roof, RTU-1-

17 and RTU-2-17.

o See previous assumption related to grouping/representing fan coil units. This applies to the 2nd, 3rd, 4th, and 5th floors.

• Building 22 o Not all information was available. The load for AC-5-22 was assumed to be 60,000

BTUH. This is a former lab unit.

• Ice Storage Plant o The plant is included for illustration within the model. It is not connected to the main plant output and overall loads.

• Building 23 o No information was available for sizing the air handling units.

• Building 24 o The two chilled water pumps, four fan coil units, and 24-AHU-1 are under construction as part of the new renovation (project number 595-13-106).

o The existing unit AC-24-1 is provided chilled water directly from the main plant.

• Building 101 o There are two new units that are shown on the model. The areas served by these units are under construction, so the units are not calculated as part of the overall model.

• Building 104 o There are two new units that are shown on the model. These future loads were noted from project number 595-390 and are shown on sheet M-701R6 Chilled Water

Schematic for Building 104.

The equipment ranges in ages from five to 20 years, and not all equipment could be catalogued due to lack of documentation. Due to the age of these drawing sets, some sheets were lost or illegible. There were some buildings where no information could be provided, and the assumptions were implemented.

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A breakdown of the various documents and drawings used to create the model can be found in

Appendix B.

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4.0 Building Overviews

This section provides information of the building’s use, the equipment and/or systems that utilize chilled water, and an overview of the model for that given building.

The complete chilled water system overview can be found in Appendix A, while individual building overviews can be found in Appendix C.

A complete list of all drawing sets can be found in Appendix B – Drawings Used to Create Model.

Building 10 – Chiller Plant

Building 10, shown in Figure 2 below, houses the main boiler and chiller plants for the Lebanon

VAMC. The building also contains a number of offices. The three current cooling towers in use by the plant are situated on a lower rooftop. There are plans in place to replace these towers and relocate to the ground.

Figure 2: Building 10 – Satellite Image

Inside the chiller plant portion of this building there are two water-cooled Trane chillers totaling

1,980 nominal tons. The primary chilled water loop contains three (3) 100-horsepower primary pumps (P-1, P-2, and P-3) located inside Building 10, with most perimeter buildings having a secondary pumping system located in the building’s respective basement. There are several air-cooled chillers located around the campus which provide cooling to individual air handling units.

For instance, there is an air-cooled chiller on the 2nd floor roof of Building 1 which supplies chilled water to the Building 101 air handling units. Campus chilled water acts as backup in this scenario.

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In addition to the existing Evapco cooling towers, the condenser water loop consists of three (3)

75-horsepower pumps (P-4, P-5, and P-6) located beside the primary chilled water pumps in the main chiller plant.

The chiller plant equipment is tied to the Trane Tracer building automation system (BAS), while nearly all other equipment for the facility is tied to the Delta BAS.

An overview of Building 10’s model is provided in Figure 3 below. A larger image of this building overview can be found in Appendix C. Chilled water leaves the west end of Building 10, traversing to just north of Building 2 where the piping is accessible via the pipe vault. From the vault, the piping branches off to the other regions of the campus.

Figure 3: Building 10 – Model Overview

At the beginning of this investigation, Alares was informed that the chiller plant would be undergoing construction in the near future. Most notably, the cooling towers were to be replaced

(project number 595-11-135, Cooling Tower Replacement, dated August 8th, 2012) as well as the chillers (project number 595-15-203, Chiller Replacement, dated October 6th, 2017). All equipment inputs were selected using documentation made available for in-use equipment at the time this project began.

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Building 1 – Main Hospital

Building 1, originally constructed in 1947, acts as the main hospital. This building underwent a major renovation in 2003. The six-story building is served by 12 main air handling unit systems which have steam and chilled water provided by the central plants.

Figure 4: Building 1 – Satellite Image

The chilled water from the main plant enters into the building’s basement from the northwest through an 8” pipe and then enters into the buildings secondary chilled water pumps. Within the basement there are six (6) different take-offs from the CHW line. These lines are detailed in the table below.

Table 3: Building 1 Chilled Water Risers

CHW Line Take-off

Pipe Diameter [in] Equipment Served

Main 6”

AC-1-1, AC-2-1, AC-4-1, AC-5-1, AC-9-1, AC-11-

1, AC-12-1

FCUs on each floor

AC-3-1 + AC-6-1 3”

AC-3-1, AC-6-1

FCUs on Ground and 3rd Floor

AC-7-1 + AC-8-1 5” AC-7-1, AC-8-1

AC-14-1 2.5”

AC-14-1

Ground Floor FCUs

Bldg 101 4” RTU-1-101, RTU-2-101, RTU-3-101

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CHW Line Take-off

Pipe Diameter [in] Equipment Served

Bldg 102 3” RTU-1-102

The secondary chilled water pumps in the basement mechanical room are sized at 100 horsepower with a design GPM of 1,950 and a total dynamic head (TDH) of 145 each. These pumps were installed in 2004.

A breakdown of the equipment in Building 1 is provided in the tables below.

Table 4: Building 1 – AHU Overview

Unit CHW Coil

Total [GPM] Max WPD [ft]

AC-1-1 875.4 125.0 20.6

AC-2-1 686.0 137.0 7.0

AC-3-1 418.9 59.4 10.0

AC-4-1 486.3 69.1 15.0

AC-5-1 202.9 29.0 8.0

AC-6-1 393.0 55.8 10.0

AC-7-1 523.4 74.4 15.0

AC-8-1 410.4 58.3 10.0

AC-9-1 208.3 29.8 5.0

AC-11-1 425.0 70.0 13.5

AC-12-1 104.0 20.0 4.7

AC-14-1 116.0 17.0 5.1

ACU-1-1 20.1 5.0 6.7

ACU-2-1 11.1 5.0 5.3

Table 5: Building 1 – Pump Overview

Unit Flow

[GPM]

Head

[ft]

Motor Type

[hp] [RPM]

P-1-1 1950 145 100 1,760 Horizontal Split Case

P-2-1 1950 145 100 1,760 Horizontal Split Case

An overview of the building’s model can be found in Appendix C.

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Building 2 – Admin

Figure 5: Building 2 – Satellite Image

Building 2 serves as an administrative building for the campus and houses the Consolidated

Patient Account Center (CPAC).

There are two separate chilled water systems for this building:

• A primary building chilled water system that serves all the chilled water devices, consisting of two (2) air-cooled chillers with two (2) primary pumps and one (1) backup pump.

• A 30-ton chilled water system that consists of one (1) air-cooled chiller and two (2) constant-volume pumps which serves the data center, IT closets, and elevator equipment room.

The campus chilled water system is only available to be used by the 30-ton chiller in the event of equipment failure.

Due to this building only utilizing chilled water from Building 10 in the case of an emergency, Alares has not included it in the model. The building and equipment are shown on the model, however, as a representation.

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Building 6 – Warehouse

Figure 6: Building 6 – Satellite Image

Through discussions with the AC Shop, Alares was informed that Building 6, a warehouse, contains one unit that utilizes chilled water for cooling. Alares could not gain access to this building during its preliminary site visits.

Alares was provided various drawing sets that contained some information for this building, including:

• 595-03-104, Major/Minor Dominos, Ph III (Warehouse Addition), March 26th, 2003 o This four page drawing set does not contain any mechanical drawings or schedules.

• 595-04-102, ECC Upgrade, July 14th, 2004 o This drawing set shows two AHUs: one in Room 106A, and another in Room 105A.

o The ATC control diagrams show two units for this building utilizing chilled water for cooling purposes: one unit serving a Pharmacy Cache and one unit serving the

Warehouse

• As-built Drawings, July 16th, 2011 o Review of the mechanical as-builts shows one HVAC unit in room 106A, and one unit in Room 105A. The former unit conditions the mechanical space it is located in.

The as-builts do not show the piping entering or leaving the building, nor do they show any CHW piping supplied to the unit in Room 105A.

Based on review of available documentation, and through the discussions with the AC Shop, it was determined the chilled water load for the singular AHU in Room 106A would be negligible.

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Building 7 – Laundry

Figure 7: Building 7 – Satellite Image

Building 7 serves as the facility’s main laundry building. The lone unit that utilized chilled water within the main laundry room has been removed. Chilled water piping runs along the ceiling and is capped off where this unit used to be, possibly for future renovation.

Figure 8: Building 7 – CHW Piping to Fan Coil Unit

There was a smaller unit located in the basement that was marked up on the as-builts (dated 7-

16-2011). This unit is shown as being in a small room accessible via a rear entrance at ground level. The unit is no longer there. The chilled water piping that was marked up as running to this unit runs parallel with the building and into the other half of the basement. Alares could not access this portion of the building during its visit but was advised by the AC Shop that it served a small fan coil unit at most. Due to the size of this unit, and based on discussions with the AC Shop, Alares opted not to include the unit in the model.

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Building 17 – Ambulatory Care

Building 17 is a five-story building, originally built in 1950, that underwent a major renovation in

2003. It houses departments such as the primary care, radiology, pharmacy, and outpatient clinics. The building is served by at least seven (7) air handling units which are supplied by the central plant. Alares were unable to confirm whether the RTU-1-17 and RTU-2-17 in Building 17 were being supplied by the campus chilled water as no data was available for these units.

Therefore, they are shown on the model but are not tied into the campus load.

Figure 9: Building 17 – Satellite Image

Chilled water from the main plant enters into the building’s basement from the north through a 6” pipe and then enters into the secondary chilled water pumps. From there the chilled water exits the pump room and goes up through the main pipe riser to supply all units, apart from AC-4-17 whose piping splits from the main line before the main riser.

The secondary chilled water pumps in the basement mechanical room are sized at 30 horsepower with a design GPM of 600 and a total dynamic head (TDH) of 95 each. These pumps were installed in 2004.

A breakdown of the equipment in Building 17 is provided in the tables below.

Table 6: Building 17 – AHU Overview

Unit CHW Coil

Total [GPM] Max WPD [ft]

AC-1-17 962.3 137.5 10.0

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Unit CHW Coil

Total [GPM] Max WPD [ft]

AC-2-17 632.6 90.4 10.0

AC-3-17 505.4 72.2 10.0

AC-4-17 256.6 36.7 10.0

AC-5-17 166.6 23.8 5.0

AH-1 390.1 65.0 9.8

AH-2 311.1 51.8 5.6

RTU-1-17 No information available

RTU-2-17 No information available

Table 7: Building 17 – Pump Overview

Unit Flow

[GPM]

Head

[ft]

Motor Type

[hp] [RPM]

P-1-17 600 95 25 1,760 Horizontal Split Case

P-2-17 600 95 25 1,760 Horizontal Split Case

An overview of the building’s model can be found in Appendix C.

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Building 18 – Outpatient

Building 18 is a Behavioral Health/AD Operations building which was built in 1950. The building is conditioned by five (5) air handling units, all of which are supplied by campus chilled water.

Figure 10: Building 18 – Satellite Image

Building 18 also includes the AC Shop, where Alares spent a lot of time reviewing available documentation, accessing the building automation system, and discussing the distribution system with site personnel.

Chilled water from the main plant enters into the building’s sub-basement from the northeast through a 6” pipe and then enters into the building secondary chilled water pumps. From there, the secondary chilled water piping exits the sub-basement up through the main piping chase to the penthouse to serve AC-1-18, AC-2-18, and AC-5-18. The piping for AC-3-18 and AC-4-18 splits from the main riser at the basement level through a 3” pipe to the units on the 1st floor roof.

The secondary chilled water pumps in the basement mechanical room are sized at 30 horsepower with a design GPM of 606 and a total dynamic head (TDH) of 105 each. These pumps were installed in 2004.

An overview of the Building 18 model is shown in Figure 11 below. A larger image of this building overview can be found in Appendix C.

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Figure 11: Building 18 – Model Overview

A breakdown of the equipment in Building 18 is provided in the tables below.

Table 8: Building 18 – AHU Overview

Unit CHW Coil

Total [GPM] Max WPD [ft]

AC-1-18 980.1 140.0 10.0

AC-2-18 1,372.1 196.0 10.0

AC-3-18 423.1 60.4 15.0

AC-4-18 481.7 68.8 12.0

AC-5-18 162.0 23.2 5.0

Table 9: Building 18 – Pump Overview

Unit Flow

[GPM]

Head

[ft] Motor

Type [hp] [RPM]

P-1-18 606 105 30 1,760 Horizontal Split Case

P-2-18 606 105 30 1,760 Horizontal Split Case

Lebanon VA Medical Center

Building 19 – Police/Admin

Several facility departments have their offices located in Building 19, including the engineering department and the campus police.

Figure 12: Building 19 – Satellite Image

Chilled water from the main plant enters into the building’s basement from the west end of the building, below the connecting corridor through a 6” pipe. The piping runs northeast along the crawl space until it hits the basement mechanical room, and then enters into the building secondary chilled water pumps. From there, the secondary chilled water piping exits the basement back into the crawlspace, before takeoff through the main piping chase to the penthouse to serve

AC-1-19, AC-2-19, and AC-4-19. The piping for AC-3-19 splits from the main riser at the 1st floor level through a 2” pipe, which drops to 1.5” in diameter before shooting up to the 2nd floor roof.

The secondary chilled water pumps in the basement mechanical room are sized at 15 horsepower with a design GPM of 337 and a total dynamic head (TDH) of 75 each. Alares believes these pumps were installed in 2004.

An overview of this building model is shown in Figure 13 below. A larger image of this building

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Figure 13: Building 19 – Model Overview

A breakdown of the equipment in Building 19 is provided in the tables below.

Table 10: Building 19 – AHU Overview

Unit Capacity [MBH] CHW Coil

Sensible Total [GPM] WPD [ft]

AC-1-19 143.4 217.0 28.9 5.9

AC-2-19 125.1 171.0 22.8 2.1

AC-3-19 83.0 100.3 12.3 1.5

AC-4-19 68.4 92.4 12.3 1.0

Table 11: Building 19 – Pump Overview

Unit Flow

[GPM]

Head

[ft] Motor

Type [hp] [RPM]

P-1-19 337 75 15 1,760 Frame Mounted End Suction

P-2-19 337 75 15 1,760 Frame Mounted End Suction

Air handling unit information came from documentation for project number 595-05-133, Air

Handling Units Replacement, dated December 21st, 2010. Pump information came from documentation for project number 595-03-101, HVAC Deficiencies Chilled Water System

Corrections, dated October 15th, 2003.

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Building 22 – Education

This building serves as the Education building, and houses computer training rooms, classrooms, Informatics, the library, the LPN meeting room, Release of Information, Scanning of Medical

Records, Simulation Lab, TMS Administrators, and union offices.

Figure 14: Building 22 – Satellite Image

The building has two chilled water pumps located in the basement. These circulate chilled water from the plant to the fan coil and rooftop units. An overview of the model for this building is shown in Figure 15 below. The first, second, and third floors are conditioned by fan coil units.

An overview of the model for this building is shown in Figure 15 below. A larger image of this building overview can be found in Appendix C.

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Figure 15: Building 22 – Model Overview

A breakdown of the equipment in Building 22 is provided in the tables below.

Table 12: Building 22 – AHU Overview

Unit CHW Coil

Total [GPM] WPD [ft]

AC-3-22 275.0 53.0 7.7

AC-4-22 53.0 15.0 1.4

AHU-5 No information available

Lebanon VA Medical Center

Table 13: Building 22 – Pump Overview

Unit Flow

[GPM]

Head

[ft]

Motor Type

[hp] [RPM]

P-1-22 318 105 20 1,760 Frame Mounted End Suction

P-2-22 318 105 20 1,760 Frame Mounted End Suction

A summary of the available documentation is detailed below:

• 595-01-103, Major Dominos, May 1st, 2001 o The air handling unit schedule shows two units utilizing chilled water: AC-3-22 serving the Social Room and AC-4-22 serving the elevator penthouse.

o Sheet 22-H5 shows the roof and penthouse plan, which includes AC-1-22, AC-2-

22, AC-3-22, AC-4-22, ERU-1-22, and an RTU.

• 595-03-101, Chilled Water System Corrections, October 15th, 2003 o This drawing set provided the pump information shown in Table 13 above.

• 595-04-102, ECC Upgrade, July 14th, 2004 o Sheet H6 shows fan coil units throughout the first three floors. This sheet also shows

AC-3-22, AC-4-22, and the ERU located within the penthouse, and a Lab AHU and the RTU on the rooftop. This is inconsistent with what was observed on-site.

• As-built Drawings, June 4th, 2011 o The mechanical as-builts show chilled water being provided to fan coil units throughout the building, as well as a rooftop unit (shown on the second-floor plan, not labeled). No other units are shown utilizing chilled water on these as-builts.

• 595-15-201, Lebanon Renovate Building 22, August 27th, 2018 o Alares was provided with 35% design phase drawings for this future work.

Alares visited the equipment while on-site, and found AC-1-22 (RTU, former Lab unit), AC-3-22

(RTU, serves classrooms), AC-4-22 (serves elevator penthouse), AC-5-22 (smallest RTU), and the ERU. The units tied to the chilled water include AC-1-22, AC-3-22, and AC-4-22.

The front-end shows two units with conflicting labels: AC-5-22 (serves Room 212) and AHU-5

(serves Room 209). The former appears to be a DX cooling unit, consistent with the AC-5-22 observed on the rooftop. The latter unit looks to be a large air handling unit, with outside and mixed air dampers and preheat, cooling, and reheat coils. Alares is working under the assumption that the unit labeled AHU-5 on the BAS is the large RTU labeled AC-1 in the field.

There are no mechanical schedules available for the former lab unit AC-1/AHU-5. Alares estimated this unit’s capacity based on the building pump sizes, pipe diameters to the roof, and due to it being of a similar size to AC-4-22.

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Ice Storage Plant

The ice storage plant is situated northwest of Building 22, and is comprised of three (3) Trane air-cooled chillers, 48 CALMAC storage tanks, four (4) chilled water pumps (Pump 1 through 4) fed from the ice tanks, two (2) chilled water pumps (Pumps 5 and 6) fed from the main chilled water loop, and an economizer. Two of the chilled water pumps act as spares, one for the ice storage and one for the main chiller plant.

Figure 16: Ice Plant – Satellite Image

The building automation system enables/disables the ice storage through one of three options:

calendar scheduling, demand limiting / load shifting, or a call for cooling is enabled. There are various modes associated with the operation of the ice storage plant, including: Chiller Only mode, Tank Discharge Only mode, Simultaneous Chiller and Tank Discharge mode, Make Ice mode, Make Ice and Cool mode, Off mode.

The normal operation of the ice plant is summarized below:

The load of the central plant will be monitored at all times. During adjustable daytime operation windows, the central plant will call for an ice plant cooling contribution to the facility in order to either reduce the central cooling plant from two-chiller to one-chiller operation, from a full load to a more efficient part-load status, or to totally supplant a single chiller at low part load operation. The logic to make the determination of when and at what setpoints these transitions will take place will be addressable from the web-based graphical interface.

The above sequence comes from the Thermal Storage for Chiller Plant drawing set, project number 595-11-131, dated July 18th, 2016.

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The plant is represented in the model but could not be tied into the load due to the difficulty in creating the scenarios in which it operates and how it supplements the central chilled water system. For clarity and operation, the model operates on a design cooling day with chilled water being provided from the main plant. Alares took the additional cooling and pumping provided by the ice plant into its consideration when assessing how the overall chilled water system operates and whether there is sufficient load.

An overview of the ice storage plant model is shown in Figure 17 below. A larger image of this

Figure 17: Ice Plant Storage – Model Overview

A breakdown of the equipment for the ice storage plant is provided in the tables below.

Table 14: Ice Storage Plant – Chiller Overview

Unit Nominal

Tons M/N S/N Type

Chiller #1 350

RTAC 3504 UX0N UAGN L1TY

1CDB ND6U N10N N0EX N

U13B05612 Air-Cooled Rotary Chiller

Chiller #2 350 U13B05614

Chiller #3 350 U13B05613

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Table 15: Ice Storage Plant – Pump Overview

Unit Flow

[GPM]

Head

[ft]

Motor Type

[hp] [RPM]

Pump 1 865 85.7 40 1,775 Armstrong Pumps for Ice Storage, Horizontal End-Suction Pump, Close-Coupled Motors

Pump 2 865 87.3 40 1,775

Pump 3 865 86.6 40 1,775

Pump 4 845 85.5 40 1,775

Pump 5 2,020 67.0 125 1,780 Armstrong Pumps fed from CHW Loop, Horizontal Split-Case Double Suction Pump, Base Mounted Pump 6 2,020 67.0 150 1,780

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Building 23 – Admin

This administrative building houses the Barber Shop, Employee Health, EMS, Escort Office, Mail

Room, Interior Design Office, Print Shop, TBI/Polytrauma Clinic, Veterans Rehab Center, VRRP

Conference Room, and Wheelchair Repair.

Figure 18: Building 23 – Satellite Image

There are four rooftop units that condition air for the building with chilled water cooling. The basement mechanical room has two chilled water pumps, CHP-1 and CHP-2. An overview of the model for this building can be seen in Figure 19 below. A larger image of this building overview can be found in Appendix C.

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Figure 19: Building 23 – Model Overview

No documentation for this building’s air handling units was available. A placeholder table for these units is provided below and will be updated if information is made available.

Table 16: Building 23 – AHU Overview

Unit Capacity [MBH] CHW Coil

Sensible Total [GPM] Max WPD [ft]

RTU-1-23 No information available

RTU-2-23 No information available

RTU-3-23 No information available

RTU-4-23 No information available

Pump and motor nameplate information is summarized in the table below. The pump nameplates were partially covered in debris/rust.

Table 17: Building 23 – Pump Overview

Unit Flow

[GPM]

Head

[ft] Motor

Type [hp] [RPM]

CHP-1 82 3 1,760 Vertical in-line

CHP-2 82 3 1,760 Vertical in-line

Due to the lack of documentation on the air handling units, assumptions were made based on the sizes of basement piping and the chilled water pumps, which are sized for 82 GPM. Alares gave each unit a conservative load of 100,000 BTU/hr for the purposes of the model.

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Building 24 – YMCA

Building 24 is the location of the facility’s fitness center, gymnasium, and pool. This building also houses “YMCA at the VA”. Much of this building was under construction while Alares surveyed the chilled water equipment within the building.

Figure 20: Building 24 – Satellite Image

Alares was informed of a sauna expansion to the building. This new work includes the addition of a rooftop unit (AHU-1), two (2) associated chilled water pumps (CWP-1 and -2), and four fan coil units (FCU-1 through -4). This documentation came as a drawing set for project number 595-13-

106, Renovate for Move! Program dated May 19th, 2017. Alares included this new equipment in the model due to available information.

An overview of the model for this building is shown in Figure 21 below. A larger image of this

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Figure 21: Building 24 – Model Overview

No formal documentation was provided to or found by Alares during this investigation for the existing equipment. Based on this, Alares used the proposed unit replacement size for AC-24-1 from this design project and 24-AHU-1 size was taken from the ‘595-13-106 Renovate for Move!

Program’ proposed drawings.

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Building 101 – Hospital

Building 101 houses the emergency department, operating room (OR), and intensive care unit

(ICU) for the hospital.

The rooftop of Building 101 has three units that utilize chilled water: RTU-1-101, RTU-2-101, and

RTU-3-101, as seen in Figure 22 below. There are two newer units which have not yet been tied to the chilled water loop, per discussions with the AC Shop. One of these two units is situated in the western corner of the rooftop and will serve the SPS in Building 1, connecting Buildings 1 and

101. The other unit is visible in the image below, situated above the corridor to the southeast.

Figure 22: Building 101 – Satellite Image

Chilled water is provided to these three rooftop units from the main basement mechanical room in Building 1.

An overview of this building’s model is provided in Figure 23 below. A larger image of this building

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Figure 23: Building 101 – Model Overview

A breakdown of the equipment in Building 101 is provided in the tables below. Information for

RTU-1-101 and RTU-2-101 comes from the drawings for project number 595-455 Consolidate

ICU and Urgent Care, dated June 15th, 2005. No information was available for the third RTU or the two newer units.

Table 18: Building 101 – AHU Overview

Unit Capacity [MBH] CHW Coil

Sensible Total [GPM] Max WPD [ft]

RTU-1-101 219.5 316.0 44.9 6.7

RTU-2-101 400.8 680.0 96.7 7.5

RTU-3-101 No information available

New Unit No information available

New Unit No information available

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Building 102 – Rehab

Physical therapy and rehabilitation are located in Building 102, along with the occupational therapy clinic, prosthetics and sensory aids, and the facility’s loading dock.

Figure 24: Building 102 – Satellite Image

Chilled water is provided to Building 102 from the secondary chilled water pumps in the basement of Building 1. Shown below are the pipes going up to the 1st floor.

Figure 25: Chilled Water Piping from Building 1 to Building 102

An overview of this building’s model is shown below. A larger image of this building overview, and how it is connected to Building 1, can be found in the appendices.

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Figure 26: Building 102 – Model Overview

This building contains one air handling unit that utilizes chilled water cooling. This unit is detailed in the table below.

Table 19: Building 102 – AHU Overview

Unit Capacity [MBH] CHW Coil

Sensible Total [GPM] Max WPD [ft]

AC-1-102 458.2 587.3 83.2 15.4

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Building 104 – Hospital

Building 104 is the Ambulatory Surgery Unit (ASU), or Ambulatory Care. This building has undergone recent renovations. During Alares’ March site visit, the AC Shop informed Alares that only the first floor was operational.

Some of the documentation reviewed for this investigation shows this building previously being named Building 103. Alares progressed under the assumption that all documentation for Building

103 should be treated as documentation for Building 104.

Figure 27: Building 104 – Satellite Image

Chilled water piping for Building 104 comes from the main plant via the pipe vault north of Building

2. This is one of the three branches that come out of the pipe vault. The chilled water piping runs southeast from the vault to Building 104, entering at the north corner.

The secondary chilled water pumps CHWP-1-103 and CHWP-2-103 are located in the building’s interstitial 2nd floor, along with most of the air handling units. Chilled water is circulated through the pumps before dropping down below the floor for distribution. Once the piping arrives at the location of an air handling unit, it flows back up to the interstitial level to be provided to the unit.

An overview of the model for Building 104 is shown in Figure 28 below. A larger image of this

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Figure 28: Building 104 – Model Overview

A breakdown of the equipment in Building 104 is provided in the tables below.

Table 20: Building 104 – AHU Overview

Unit Capacity [MBH] CHW Coil

Sensible Total [GPM] WPD [ft]

AHU-1-103 No information available

AHU-2-103

471.0 600.0 60.0 --

471.0 600.0 120.0 --

AHU-3-103 392.0 554.0 45.0 --

AHU-3N-104 458.0 584.0 116.9 4.93

AHU-4-103 167.0 284.0 27.0 --

AHU-5-104 589.0 818.0 163.0 7.2

Oncology AHU No information available

New Unit No information available

New Unit No information available

Table 21: Building 104 – Pump Overview

Unit Flow

[GPM]

Head

[ft]

Motor Type

[hp] [RPM]

CHWP-1-103 1,800 60 40 1,750 Basemount End Suction

CHWP-2-103 1,800 60 40 1,750 Basemount End Suction

Information for this equipment came from the following drawing sets:

• 595-390, Expand Surgery Services, 8-19-2010

• 595-10-105, Renovate 1-2 Bed Unit, 5-14-2012

• 595-335, Construct ICU, Medical, Surgical Bed Units, 7-16-2015

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Building 106 – Chapel

Figure 29: Building 106 – Satellite Image

Through conversations with the AC Shop and survey of equipment, it was determined the Chapel is conditioned by a combination of 106-AC-1 (labeled AHU-1 in field) and a split-system unit. The

DX cooling serves the perimeter offices, while the chilled water air handling unit 106-AC-1 serves the actual chapel space.

The AHU is located in the rear mechanical room, accessible via an exterior set of double doors.

This mechanical space had previously included a chiller and cooling tower, which provided chilled water to the AHU. The chiller/cooling tower have since been removed, and the AHU has been tied into the chilled water loop. There are no pumps in this space for the chilled water.

An overview of this building within the model is provided in Figure 30 below. A larger image of this building overview can be found in Appendix C.

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Figure 30: Building 106 – Model Overview

A breakdown of the equipment in Building 106 is provided in the tables below. The only information made available for this AHU comes from the original drawings dated February 28th, 1962 (project number 37-5345).

Table 22: Building 106 – AHU Overview

Unit Capacity [MBH] CHW Coil

Sensible Total [GPM] Max WPD [ft]

106-AC-1 -- 259.0 65.0 --

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Building 136 – IT

Building 136 houses the facility’s IT service (FITS). There is one chilled water unit, AC-1-136, located outside of the building.

Chilled water is pumped into the north corner of the building and runs southeast to the rear mechanical room. Chilled water is pumped through P-1-136 and P-2-136 to the air handling unit.

These pumps are located in the small exterior mechanical room, with AC-1-136 being outside and adjacent to that room.

Supply air is distributed back into the building to variable air volume boxes. The white supply duct is visible in the satellite image in Figure 31 below.

Figure 31: Building 136 – Satellite Image

An overview of the building’s model is shown in Figure 32 below. A larger image of this building

Figure 32: Building 136 – Model Overview

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A breakdown of the equipment in Building 136 is provided in the tables below. This data, which was used for the model, came from project number 595-03-107 HVAC Deficiencies Air Handling

Unit Replacements drawings.

Table 23: Building 136 – AHU Overview

Unit Capacity [MBH] CHW Coil

Sensible Total [GPM] WPD [ft]

AC-1-136 249.0 331.1 82.0 10.0

Table 24: Building 136 – Pump Overview

Unit Flow

[GPM]

Head

[ft] Motor

Type [hp] [RPM]

P-1-136 82 40 2 1,750 Vertical in-line

P-2-136 82 40 2 1,750 Vertical in-line

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5.0 Model Results

This section discusses the model and investigation findings. Three site investigation visits were conducted to collect equipment data and trace out secondary loop chilled water piping. Alares surveyed as much of the chilled water secondary system that was accessible.