Attachment B CDP Facilities Description.pdf

CENTER FOR DOMESTIC PREPAREDNESS

FACILITY OPERATIONS AND SUPPORT SERVICES

ATTACHMENT B

FACILITIES DESCRIPTIONS

Revised October 12, 2018

I

CONTENTS

INTRODUCTION

MAIN COMPLEX (BUILDING 61)

Overview

Building Envelope

HVAC Systems

Lighting Systems

Domestic Hot Water

Water Consuming Equipment

EMS

ADVANCED RESPONDER TRAINING COMPLEX (ARTC)

Overview

Building envelope

HVAC Systems

Lighting Systems

Domestic Hot Water

Water Consuming Equipment

EMS

CHEMICAL ORDNANCE BIOLOGICAL RADIOLOGICAL (COBRA) TRAINING

FACILITY

Overview

Building Envelope

HVAC Systems

Lighting Systems

Domestic Hot Water

Water Consuming Systems

EMS

NOBLE TRAINING FACILITY (NTF)

Overview

Building Envelope

HVAC

Lighting Systems

Domestic Hot Water System

Water Consuming Systems

EMS

Kitchen Area

LODGING COMPLEX

II

Overview

Building Envelope

HVAC Systems

Lighting Systems

Domestic Hot Water

Water Consuming Equipment

EMS

WAREHOUSE (BUILDING 40)

Overview

Building Envelope

HVAC Systems

Lighting Systems

Water Consuming Equipment

MECHANICAL EQUIPMENT SUMMARY

INTRODUCTION

This document includes a description of the existing conditions for the Center for Domestic Preparedness (CDP) campus. Due to continuous upgrading, renovating, and new construction, this document may not capture the results of these actions and changed conditions of recent and on-going improvements.

The CDP campus contains several buildings with varying functions. The six main building areas on the campus are the Main Complex (bldg. 61); Advanced Responder Training Complex (ARTC); Chemical Ordnance Biological Radiological Training Facility (COBRATF); Noble Training Facility (NTF); Warehouse (Bldg. 40);

and the Lodging Complex. These six areas are discussed in the following subsections. Each building area description includes the building square footage; original construction date; building envelope characteristics;

heating, ventilating, and air conditioning (HVAC) equipment used to condition the building; lighting systems;

and domestic hot water (DHW) generation equipment.

Areas not included in this document include dormitory building 78 within the Lodging Complex and Buildings 640 (500), 160 (501), and 333 (504) in the Advanced Responder Training Complex (ARTC). Dormitory building 78 is excluded because it is currently not occupied. Buildings 640 (500), 160 (501), and 333 (504) are excluded because they are not occupied or are used primarily as warehouse space.

MAIN COMPLEX (BUILDING 61)

Overview

Building 61 is the main headquarters for the CDP campus and has a total conditioned floor space of 232,990 square feet including the guardhouses. The main building has three distinct sections, which were originally constructed in 1954, 1977, and 1986. The original 1954 section, known as Faith Wing, is 37,729 ft2 and has a combination of offices on the first floor and training spaces on the second and third floor. Faith Wing was completely renovated in 2016. The 1977 addition has 42,600 ft2 of floor space used for logistics and storage on the first floor and training classrooms on the second floor. The 1986 addition has 151,685 ft2 of floor space used for office space, classrooms/training venues, a cafeteria, and conference rooms.

Building 61 has two guardhouses; one in the front of the building (61A) and one in the rear (61B). The main guardhouse building 61A has a total of 916 ft2, was built in 2005 and renovated in 2008. The rear guardhouse (61B) is 60 ft2.

Building 61 is generally occupied between 6 am and 6 pm, Monday through Friday. The building is normally closed on Saturday and Sunday; however, during periods when a Personnel Mobility Center (PMC) is established for active Federal disasters, the building may be occupied through the weekends, which could last for several weeks. The building’s occupancy levels are variable depending upon the training and classroom space needs and on training days the building occupancy level is often 500 people or more.

Building Envelope The building was constructed with cast-in-place (CIP) concrete perimeter walls and concrete masonry unit walls with steel columns to support the structure. The exterior walls are finished with a stucco veneer. The insulation of the walls varies based upon the time of construction / major renovation.

The flat roofs for the 1986 and 1977 sections of Building 61 are white PVC membrane. The flat roof for a majority of the Faith Wing was not altered during the construction beyond new gutters and downspouts, however a new flat roof for the auditorium on the north end of the building was installed in 2016.

The entry area windows of the 1986 addition are an aluminum-framed storefront system that includes the entry doors. The windows and doors are double-glazed panes set in metal frames. The remaining building windows for the 1977 and 1986 additions are aluminum-framed thermally broken double glazed fixed units. New windows were installed in the Faith Wing during the 2016 renovation. The windows have either aluminum or steel bullet resistant frames.

HVAC Systems The building has three distinct heating, ventilating, and air conditioning systems. A centralized chiller plant is located in the 1977 and 1986 additions. A central heating water plant is located in the 1977 addition, 1986 addition and the Faith Wing.

Chilled water for 1986 addition is supplied by two fully redundant Trane 220-ton helical rotary water-cooled chillers manufactured in 2013. Chillers are located in room 1030 in the 1986 section of the building and provide chilled water to the five air handling coils located in mechanical rooms 2030 and 2009. The 2-20 HP chilled water pumps operate in a lead / lag configuration and are controlled by VFDs. The chillers are supplied condenser water by 2-10HP condenser water pumps fed by an Evapco 2-cell cooling tower located in the rear of the building.

The cooling tower 10HP fan motors are controlled by VFDs mounted on the wall of mechanical room1030 next to the VFDs for the chilled water pumps. All the cooling plant equipment for the 1986 addition is of relatively recent vintage and in good working condition.

Exhibit 1. Chiller Serving 1986 Addition

The 1977 addition has chilled water generated by a single 100-ton air cooled chiller built by Trane in 2012. The 100-ton chiller is located outside of mechanical room 133 and provides chilled water to the two air handling units (AHUs) serving the 1977 addition located in rooms 133 and 237. The 5 HP primary chilled water pump (CPP-1) feeds the secondary 10HP chilled water pump (CSP-1) and is controlled using a VFD.

Cooling and ventilation for the Faith Wing is achieved through 5 rooftop units (RTUs) installed during the 2016 renovation of the building. The RTUs are equipped with integral DX cooling and do not provide heating to the respective spaces. RTUs 1 through 4 serve the 2nd and 3rd floors and are all 10-ton units, while RTU-5, a 5-ton unit, serves the Faith Wing auditorium. The RTUs deliver conditioned air to 27 VAV boxes located throughout the 2nd and 3rd floors. Each VAV box is equipped with a heating water coil, which is the only source for heating in the Faith Wing. The RTUs are equipped with these energy efficient options:

VFDs on the 7.5HP supply fans for RTU-1 to RTU-4 and the 3HP supply fan for RTU-5.

CO2 sensors on the return airstream for ventilation override Dual bulb 0-100% economizers

Heating for the Faith Wing is generated by two Lochinvar 746.4 MBH condensing boilers, which were installed in 2016. Each boiler is equipped with a ¾ HP primary heating water pump (BP-1 and BP-2 respectively). The primary pumps feed two heating water zone loop pumps (P-1 and P-2), which are operated in a lead lag configuration. The zone pumps are controlled with VFD. The loop pumps provide heating water to the 27 VAV boxes within the Faith Wing. These heating water pumps and condensing boilers are located in room 108.

Heating for the 1977 addition is provided by two redundant conventional copper fin Lochinvar boilers that were installed in 2017 with an output rating of 1017 MBH. These boilers are located outside of room 133 next to the 100-ton air cooled chiller. The boilers are equipped with a common primary fractional HP primary heating water pump. The heating water generated by these units is delivered to the 2 AHUs by the 5HP secondary heating water supply pump (HP-1) located in room 133. The secondary heating water pump output is controlled with a VFD.

Heating for the 1986 addition is provided by two redundant conventional copper fin Lochinvar boilers that were installed in 2017 with an output rating of 1454 MBH. These boilers are located outside of room 1030 near the rear entrance of the cafeteria. The heating water generated by these units is delivered to the 5 AHUs and the 130 fan powered induction units (PIUs) in the 1986 addition. Each boiler is equipped with a fractional HP primary heating water pump. The heating water is circulated through the building by 2 – 5HP secondary pumps (HWP-1 and HWP-2) operating in a lead lag configuration. The secondary heating water pumps are not controlled by a

VFD.

The conditioned air for the 1986 addition is provided by five air handling units: AHU-1 through AHU-6. Note:

AHU-4 is currently not used due to a training venue in the area served by AHU-4 which utilizes simulated smoke.

The units range from 19,000 – 30,000 CFM, and, with the exception of AHU-4, were refurbished in 2015. During the refurbishment, the hot and chilled water coils, insulation (interior of AHUs and mechanical rooms), and motors were replaced, new supply/return fan inverter – duty motors were installed with VFDs. These 5 AHUs supply conditioned air to the 130 PIUs on the 1st and 2nd floor of the 1986 addition.

The conditioned air for the 1977 addition is provided by two air handling units: AHU-1 and AHU-2. These AHUs were replaced in 2012 and are equipped with 15 HP and 10 HP supply fans respectively. The supply fans are controlled by VFDs and are not equipped with return fans. Each AHU has CO2 sensors in the return airstream and has economizing capability. The total airflow capacities are estimated at 6,500 cfm for AHU-2 and 3,000 cfm for AHU-1.

Lighting Systems

The classrooms, offices, and training rooms within the 1986 addition are lit using a combination of approximately 417 2-lamp, 775 3-lamp, and 248 4-lamp, linear fluorescent fixtures with 4-ft T8 bulbs and electronic ballasts.

The lobby entry area of the 1986 has 9-175W metal halide lamps. Some T12 lighting with magnetic ballasts remains in the mechanical rooms. All lighting is controlled by wall switches in the 1986 addition and is regularly switched off when unoccupied. All lighting is switched off except for egress lighting between 6 pm and 7 am.

The 2016 renovation of the Faith Wing included a combination of fluorescent T8 and LED lighting fixtures.

Specifically, the area has a combination of approximately 104 2-lamp and 120 3-lamp linear T8 fluorescent fixtures with 4-ft bulbs and electronic ballasts. The T8 lamps are assumed to be 32W each. Other notable high-count lighting fixtures in the area includes 83, 2 lamp linear T5 fluorescent fixtures with 2-ft bulbs and electronic ballasts, 114 compact fluorescent 32W lamps, and 45 fixtures with 2 U-shaped T8 lamps per fixture.

The classrooms in the 1977 addition and the building’s hallways use 4-ft T8 bulbs.

Exterior wall pack lighting on Building 61 is achieved by 26 new LED lights rated at 51 W each. Exterior pole lighting includes HPS lamps along the perimeter. The Faith Wing parking area includes 18 – 140W and 2 -280W metal halide lamps.

Domestic Hot Water

Domestic hot water for the 19 bathroom sinks and 6 showers in the 1977 addition is provided by three 50-gallon, 4500W electric water heaters in the second floor mechanical room (room 237). The 1986 addition has a single 100 gallon, 199 MBH gas-fired water heater in room 1030 serving the 49 bathroom sinks and the 3 kitchen sinks.

The Faith Wing has a single 130 gallon, 300 MBH input gas-fired water heater in the 1st floor mechanical room providing hot water for the 15 bathroom sinks on the 2nd and 3rd floors and the six showers on the 3rd floor.

Water Consuming Equipment Potable water is consumed for the 83 bathroom sinks, 2 janitor sinks, 3 kitchen sinks, 12 showers, 93 toilets, and 38 urinals in building 61. There are also 25 water fountains in the building (12 on the first floor, 13 on the second floor). Additional water is consumed for the cooling tower to offset any evaporated water and drift that occurs during cooling tower operation. There is also a sprinkler system for a portion of the grass area in the front of building 61.

EMS

The HVAC system for the Faith Wing, the 1986 addition, and the 1977 addition is controlled by a building automation system (BAS). All of the controls for the building are direct digital control (DDC) based.

The following items are on the BAS / EMS:

AHU summary for AHU-1, 2, 3, 5, & 6 serving the 1986 addition.

AHU-1 and AHU-2 serving the 1st and 2nd floors respectively of the 1977 addition.

VAV schedules for units 1-1 through 1-8 that are connected to AHU-1 and for units 2-1 through 2-12 that are connected to AHU-2 Chilled water plant equipment for the 1977 addition, which includes the chiller, primary pump (CPP-1), and secondary pump (CSP-1).

Heating water plant equipment for the 1977 addition, which includes the boilers, primary pump, and secondary pump (HP-1).

RTU-1 through RTU-5 serving the Faith Wing 27 VAV boxes serving the Faith Wing CO2 levels in 8 rooms on the 2nd floor of the Faith Wing (rooms 215, 217, 218, 220, 223, 225, 227, and

234) and in 8 rooms on the 3rd floor of the Faith Wing (rooms 301, 309, 310, 311, 312, 313, 315, and 324) Heating water plant equipment for the Faith Wing, which includes the boilers, primary pumps, and zone pumps.

The following equipment is not included in the BAS:

Graphical displays for AHU-1, 2, 3, 5, & 6 serving the 1986 addition The 130 PIUs serving the 1986 addition connected to the 5 active AHUs Chilled water plant equipment serving the 1986 addition, which includes the 2-220-ton chillers, the 2-

20HP chilled water pumps (CHWP-1 and 2), the 2-10HP condenser water pumps (CWP-1 and 2), and the 2 cooling towers with the 10HP tower fans.

Heating water plant equipment serving the 1986 addition, which includes the 2 copper fin boilers, the 2- 5HP secondary heating water pumps, the 2 primary heating water pumps.

Control strategies for the 2016 Faith Wing addition include:

- Hot water reset for the condensing boiler plant

- RTUs include dual enthalpy / temperature economizer control

- RTUs include demand controlled ventilation

Night-setback controls are in place for all areas of the building.

Exhibit 2. Example Control Screen for Building

ADVANCED RESPONDER TRAINING COMPLEX (ARTC)

The Advanced Responder Training Complex (500 Area) is a collection of 6 buildings that were originally leased by the CDP in 2006. These buildings are referred to by either their 911 address number or the Ft. McClellan building number, both of which are listed in the table below for reference.

Exhibit 3. ARTC Building Reference

911 Address Number Ft. McClellan Bldg.

Number

640 Freemont Rd (500) 160S Goode Road (501S)

160N Goode Roade (501N) 162 Goode Road (502) 363 Wall Street (503) 333 Wall Street (504) 303 Wall Street (505)

Buildings 640 (500), 160 (501), 162 (502), 363 (503), and 333 (504) were built in 1977; building 303 (505) was built in 1986. ARTC Bldg. 303 (505), Bldg. 363 (503), and Bldg. 162 (502) are currently used for training on a regular basis; the other buildings are used for storage and some limited training on an as-needed basis. Building 303 (505) is a mix of office and classroom space, with areas staged as models of city infrastructure. Building 363

(503) is a mix of classroom and office spaces. Building 162 (502) is staged as a model office park.

Building 640 (500), 160 (501), and 333 (504) have undergone past iterations of selective demolition for lead and asbestos abatement resulting in original as-built HVAC, plumbing, and, to a degree, electrical systems being incomplete and non-operational. However, building 333 (504) has retrofit HVAC equipment connected to Niagra 4 EMS to include an AHU, Fan Coil unit, and ventilation unit with heating.

Building envelope

The building envelope for both ARTC buildings generally consists of stucco-finished, load-bearing concrete masonry walls and interior steel columns, with flat PVC membrane roofs. Windows and doors are double glazed, with aluminum frames.

HVAC Systems

Building 162 (502) utilizes a VRF system, with two Mitsubishi Citi Multi outdoor units (1-10 ton unit, and 1-8 ton unit).

Building 363 (503) has a 125 ton air-cooled Trane Series R Chiller, and Trane AHU. The York water cooled chiller located within the mechanical space and Evapco cooling tower have been decommissioned. The chiller plant serves Buildings 363 (503), 333 (504), and 303 (505). There is 1-40 HP primary chilled water pump with VFD. There is also a 3 HP circulating pump, without a VFD. This building also has a Weil-McClain boiler, which supplies heat to Building 363 (503) and 333 (504). The boiler is rated at 515 MBH. There is a single primary hot water pump, which has a 10 HP motor and does not have a VFD.

Building 303 (505) has a Weil-McClain boiler built in 2007, which supplies hot water heating to the building.

The boiler is rated at 515 MBH. There is a single primary hot water pump (5 HP) without a VFD. Space conditioning is provided by two Trane AHUs, one of which serves the first floor (AHU-2) and one which serves the second floor. These AHUs were retrofitted to VAV systems between 2010 and 2012, and both have VFDs on the supply fans and economizer dampers.

Lighting Systems

Most of the classrooms, offices, and training rooms within the ARTC buildings use linear florescent lighting.

There is a combination of 8-ft fluorescent fixtures, as well as 4-foot fixtures with 2-lamp, 3-lamp, and 4-lamp configurations. The 4-foot fixtures are being retrofit with T8 bulbs and electronic ballasts as they burn out, but there are still many that use the original T12 bulbs and magnetic ballasts. The high bay area of building 303 (505) uses 250W induction fixtures. Exterior lighting is provided by 150W – 400W high pressure sodium and metal halide fixtures. Most lighting is controlled by wall switches and regularly switched off when buildings are not in use. The induction fixtures located in the high bay are controlled by occupancy sensors. Exterior lighting is controlled by photo sensors.

Domestic Hot Water

Water heating for Building 303 (505) is provided by an 80-gallon electric hot water heater. Building 160 (501) has a hot water heat exchanger that is not used. All other existing equipment within Bldg. 160 has been decommissioned or rendered inoperable by selective demolition.

Water Consuming Equipment

Potable water is consumed for the total of 23 sinks, 23 toilets, and 5 urinals in the buildings. This includes the following:

Building 162 (502) – 5 sinks, 5 toilets

Building 363 (503) – 7 sinks, 8 toilets, 1 urinal

Building 303 (505) – 11 sinks, 10 toilets, 4 urinals

EMS

The HVAC systems for Building 363 (503) and Building 303 (505) are controlled by the Niagra 4 building automation system (BAS).

The following items are on the BAS / EMS:

HVAC summary and occupied / unoccupied set-points for Building 363 (503) and Building 303 (505) Floorplan layouts for Building 363 (503) and Building 303 (505), including equipment locations AHU-1 and AHU-12 serving Building 363 (503), including diagram and set-points.

Chilled water plant equipment for Building 363 (503), which include the chiller and primary pump.

Heating water plant equipment for Building 363 (503), which include the boiler and primary pump.

AHU-2 serves 1st floor of Building 303 (505), and AHU-3 serves the 2nd floor of Building 303 (505), including diagram and set-points.

Heating water plant equipment for Building 363 (503), which includes the boiler and primary pump.

Control strategies included for the buildings:

Scheduled occupied / unoccupied settings AHUs include economizer control

Exhibit 4. Example Control Screen for Building 303 (505)

CHEMICAL ORDNANCE BIOLOGICAL RADIOLOGICAL (COBRA) TRAINING FACILITY

The COBRA Training Facility is located at 801 Walt Phillips Drive and is where the CDP offers the only hands-on civilian training program in the nation with access to live chemical agents and biological materials. The COBRA Training Facility was constructed in 1986 and consists of three main buildings: Administration Building (801B), Training Building (801C), and Operations and Maintenance Building (801E). Support buildings include the Guard House (801A), Dress out Building (DOB), Generator Building, Storage Building, Post 5, and Incinerator Building (801D).

Most of the building usage occurs five days per week, year-round. The normal operation hours for training are 7:00 am to 3:30 pm, while summer training hours are 6:00 am to 2:30 pm. There is also full maintenance staffing from 6AM to 5PM, Monday through Friday. Training operations and support staffing vary based on course program of instruction and individual course schedules and may include weekends, holidays and night shifts.

Exhibit 5. Site Plan COBRA TF

The Guard House (801A) is a one-story building with a total of 389 square feet.

The Administration Building (801B) is a one-story structure containing offices, two training classrooms and the medical office for the COBRA training facility site. The Admin Building operates Monday through Friday, 6 AM to 5 PM, and is staffed by 90 full time employees; it serves an estimated 50 students each week.

The Training Building (801C) is a one-story structure with a mezzanine level and unconditioned attic space. It contains the safety control office, live agent training bays, showers, chemical agent labs, and air monitoring facilities. The Training Building is staffed by an estimated 50 employees, and serves 40 to 60 students, over three to five, eight-hour days per week. To the west of the building is the Filter Pad area, which is a covered, open-sided building containing the 9 bag-in, bag-out filter stations and 10 exhaust fans that serve the multiple training bays within the Training Building. Adjacent to the Filter Pad on the south end is a CMU building containing the motor control center for the Filter Pad.

The Incinerator Building (801D) is a one-story warehouse with mezzanine levels for accessing mechanical equipment. It contains mechanical equipment, three steam boilers, large autoclaves, and the incinerator. One of the steam boilers and the incinerator have been decommissioned since May 2015. The building is open to the outside.

D O B

The O&M Building (801E) is a two-story structure that serves as the main maintenance building and contains offices for five workers, as well as workshops and break rooms. Building operations are Monday-Friday, 6 AM to 5 PM.

The Dress Out Building is a small, one-story building that houses restrooms and serves as additional space for training and equipment storage.

Building Envelope

The buildings were constructed using concrete slabs-on-grade with concrete masonry unit (CMU) walls. The roofs are constructed using steel framing. The Administration Building has a brick veneer façade and the Incinerator Building has a steel corrugated exterior wall.

The Administration Building has windows and doors with single glazed panes in metal frames. The entry area windows for the Administration Building are part of an aluminum-framed storefront system that includes the entry doors. The other buildings have few or no windows on their exteriors.

The building roofs for the space-conditioned O&M Building, Administrative Building, Dress Out Building, and Training Building are sloped. Roofs have a metal sheathing (standing seam) finish.

HVAC Systems Cooling for the Training Building is provided by two 380-ton York, MaxE Centrifugal Liquid Chillers from 2002.

Two 25 HP chilled water pumps operating in a lead-lag mode circulate the chilled water to the 3 active AHUs at the Training Building. Two EVAPCO high efficiency cooling towers are in use, one with a manufacture date of 2010, and one with a manufacture date of 2016. The 25 HP fans for the cooling towers are controlled by VFDs.

The condenser water is circulated by dual 25 HP pumps that operate in a lead lag mode.

The COBRA Training Building has strict air handling and filtering requirements that are specifically adjusted based on the agent concentrations utilized in the training bays. These areas within the Training Building require 100% ventilation air that is supplied by AHU-1, AHU-2, or AHU-14. The exhaust air from the areas that are kept under negative pressure are handled by 10 exhaust fans that are located under the Filter Pad shelter. Prior to each exhaust fan, a bag-in, bag-out filtering system removes the contaminants from the air stream. The list of the exhaust fans, equipped with variable speed drives that are set to maintain the pressure within the respective space, is shown in Exhibit 6 along with the motor size, area served, and the VSD output frequency.

Exhibit 6. Filter Pad Exhaust Fans – COBRA TF

Exhaust Fan Area HP VFD, Hz 1 TNG Bay 7 30 42.0 2 TNG Bay 5&6 15 55.4 3 TNG Bay 3&4 15 53.8 4 TNG Bay 1&2 15 58.8 5 Cold Lab 20 17.8 6 Lab Hood Fan #2 40 29.8 7 Lab Hood Fan #1 40 25.0 8 Mask Check Area 7.5 24.9 9 Doff 20 0.0

10 Hot Laundry 15 39.9

Heating for the buildings is provided by a combination of the two 150 HP York Shipley steam boilers in the Incinerator Building, which provide steam for the autoclaves, heating the O&M building1, the domestic hot water heaters, heating water for storage rooms in the Administration Building, and heating water for AHU-14 serving the Training Building. The two steam boilers share the process steam and heating load for the COBRA TF. A 2500 MBH Cleaver Brooks Clearfire condensing hydronic boiler was installed in 2017 to serve the heating water load for AHU-1 and AHU-2 in the Training Building.

Two heating water pumps are in the mechanical room for the Training Building. One pump circulates heating water generated by the steam to hot water converter for AHU-14 and the other 3 HP pump serves the new condensing boiler loop for AHU-1 and AHU-2.

The heating and cooling demands for the Admin Building are predominately served by several split-system heat pumps that handle four zones within the building with the exception of the small area handled by the steam boiler. The air handlers are recessed in the ceilings, and the condensing units are located on the roof of the building. The heat pumps are controlled by non-programmable thermostats.

The Guard House is served by a three-ton Friedrich split type system, and a RUUD heat pump.

Lighting Systems Most of the interior lighting for the Admin Building is provided by 3-lamp, linear fluorescent fixtures with 4-ft T8 bulbs. These fixtures currently use a combination of electronic and magnetic ballasts.

The Training Facility uses a combination of 3-lamp linear fluorescent fixtures, with LED lighting in the hallway (recent replacement for 1,000W mercury vapor lamps), and 1,250W CFL lamps in the Training bays.

Lighting in the Incinerator building is provided predominately by LED fixtures that are recent replacement for 1,000W mercury vapor lamps.

Lighting in the workshop areas of the O&M building and 8-foot fluorescent lights use a combination of electronic and magnetic ballasts and 8-foot LED fluorescent replacement lights. The bays have LED fixtures. Interior office areas of the O&M building utilize 3-lamp, linear fluorescent fixtures. The lighting in the building is controlled predominantly by light switches.

Domestic Hot Water Domestic hot water for the Training Building is generated by a steam-fired hot water storage tank located in the Cold Laundry room. The source of the steam is from the PKG boilers located in the Incinerator Building. The domestic hot water is used for the laundry area and showers in the Training Building.

All other areas use storage tank type hot water heaters, with the exception of the Northville Restrooms, Post 1 Guard House Restroom, and the restrooms beside the Amphitheater located on the southeast side of Northville, which use electric DHW heaters.

Water Consuming Systems

Potable water is consumed by the 12 bathroom sinks, 1 kitchen sink, 12 showers, 10 toilets, and 7 urinals in the building. Additional water is consumed by the cooling tower to offset any evaporated water and drift that occurs during cooling tower operation.

1 The shop areas in the O&M use steam for heat. The office areas in the O&M use HVAC heat strips for heating.

EMS

During Phase 1 of a renovation of the HVAC systems in 2017, the building automation system was updated to the Niagara 4 Platform. The EMS controls AHU-1, AHU-2, the 2 chillers, the chiller water pumps, condenser water pumps, cooling towers, condensing boilers and heating water pumps serving AHU-1 and AHU-2. The EMS controls/monitors the exhaust fans and air balance within the training bays at the Training Building.

NOBLE TRAINING FACILITY (NTF)

Noble Training Facility (NTF) located at 490 Care Drive has a total conditioned floor space of 162,000 square feet. The chiller plant and boiler plant serving the building are in the adjacent NTF Mechanical Building (address 294 Wall Street), which is 4,000 square feet. There are also two separate garage/workshop buildings, one is 400 square feet and the other is 576 square feet.

The main NTF building previously served as the Army Hospital for Fort McClellan. It was originally built in several stages, starting in 1966 with additions in 1976 and 1986. The building was converted to a training site for CDP in 2007. The NTF includes various training spaces including classrooms and simulation areas, as well as administrative rooms and offices. There is also a cafeteria and dining area on the first floor.

The building is typically occupied between 6 am and 5 pm, with security personnel on site 24 hours per day, 7 days per week. The building’s occupancy levels are variable depending upon the training and classroom space needs. On training days there is often 250 people or more in the building.

Three renovation projects have recently been executed at the NTF. The first included a renovation of the isolation area on the 2nd floor that covers rooms 2000 through 2037 (new rooms 2000 through 2022). Secondly, a renovation was executed to expand the kitchen. Lastly, the majority of the building envelope was renovated and included structural and architectural enhancements. The building envelope improvements included new roof insulation in select spaces and 2” rigid insulation in select exterior walls. The windows were all previously replaced in projects completed in 2009-2011. As-built record drawings are available for review.

Building Envelope The building was constructed with concrete masonry unit walls and steel columns with a brick veneer façade.

The insulation of the walls varies based on the time of construction or major renovation. The aforementioned building envelope project increased the level of insulation on some exterior walls.

NTF has white PVC membrane roofs. Some roof modifications were made with the envelope project as noted previously.

The entry area windows are part of an aluminum-framed storefront system that includes the entry doors. The windows and doors are double-glazed panes set in metal frames. The remaining building windows are aluminum-framed thermally broken double glazed fixed units.

HVAC

The HVAC system serving the NTF is comprised of the central chiller and boiler plant and the multiple AHUs serving the 3-story NTF. The following sections discuss the existing water-side and air-side systems that serve the NTF.

Chilled water for the NTF is supplied by 3 Carrier water-cooled screw chillers located in the adjacent mechanical building. This includes two 212-ton chillers built in 2003 (Chiller 1 and Chiller 2), and one 104 ton chiller built in 2004 (Chiller 3). Chiller 1 and 2 each have a 5 HP primary pump (CPP-1 and CPP-2 respectively), while Chiller 3 has a 3 HP primary pump (CPP-3). The three chillers feed 2 separate secondary chilled water loops that are connected within the main building at NTF. The 2 – 50 HP secondary chilled water pumps feeding loop 1, CSP-1A and CSP-1B, and the 2 – 30 HP pumps feeding loop 2, CSP-2A, and CSP-2B, are both operated in a lead lag configuration. The four secondary pumps are controlled by VFDs, while the primary pumps are fixed speed.

The chillers are provided condenser water by an Evapco 2-cell cooling tower located adjacent of the mechanical building. The 2 – 10 HP cooling tower fan motors are not controlled by VFDs. Two of the three condenser water pumps, which are both 15 HP, are located in the pit of the mechanical room feed the common condenser loop for all 3 chillers. The third condenser water pump, which is 10 HP, is dedicated to Chiller 3.

Exhibit 7. Chiller 1 Serving NTF

NTF is served by four natural gas fired condensing boilers. The boilers are Raypak Xtherm units built in 2013, which each have an output capacity of 1919 MBH. The burners have a 4 to 1 turndown ratio. Only one boiler is normally needed to meet peak heating loads. The boilers are equipped with hot water reset control. Three 7.5 HP zone heating pumps provide heating water to the main building. Two of the three zone heating pumps are used to serve the air handling units, while the third pump is connected to the domestic hot water heating station.

Exhibit 8. Condensing Boiler Serving NTF

Most of the conditioned air for the NTF main building is provided by seven air handling units: AHU-1 – AHU-5 (AHU-6 is not in operation), AHU-7, and AHU-8. All AHUs, with the exception of AHU-7, are hot deck/cold deck type units. These units range in capacity between 7,485 CFM and 32,125 CFM. Most of the supply and return fans for these AHUs are controlled with VFDs. In addition to these AHUs, there is also an RTU serving the classrooms on the 3rd floor.

Unit ID Supply Fan, HP Return Fan, HP CFM Capacity, MBH

AHU-1 40 7.5 21,115 877

AHU-2 50 10 27,460 942

AHU-3 40 7.5 20,005 994

AHU-4 30 7.5 16,115 571

AHU-5 20 7.5 13,345 496

AHU-7 10 n/a 7,485 259 AHU-8 50 (est) 15 (est) 32,125 192

The dining hall, major hallways and corridors on the first floor, and many of the basement rooms were upgraded with LED light fixtures in 2017. Additional LED upgrades were made during renovations for the kitchen and parts of the second floor.

Most of the rest of the interior lighting for NTF is provided by a combination of 2 – and 3- and 4-lamp, linear fluorescent fixtures with 4-ft T8 or T12 bulbs. There are approximately 135 2-lamp, 208 3-lamp, and 1688 4-lamp, linear fluorescent fixtures with 4-ft T8 bulbs. There are also approximately 305 2-lamp, and 319 4-lamp fixtures with 4-ft T12 bulbs. Most of the T8 fixtures currently use electronic ballasts, while the T12 fixtures are equipped with magnetic ballasts. The remaining rooms mostly use U-shaped T8 bulbs and CFL screw-in lamps.

Lighting in most rooms is controlled with manual switches.

Domestic Hot Water System

Domestic hot water is used for handwashing and in the kitchen area for food preparation and cleaning. There are showers in some bathrooms, they are generally not used. The kitchen has a separate DHW system, which will be modified during a major renovations scheduled to be complete in early 2019. The DHW for other building areas is provided by an Alfa-Laval indirect (water-to-water) heat exchanger located in the basement mechanical room (room 0052), which was installed in 2001. There is a 500 gallon storage tank for DHW.

The DHW system uses warm heating water at 100°F from the boiler plant during the non-heating season to generate DHW at an assumed temperature of 90°F during the summer. DHW should be maintained at 140°F within the storage tanks and delivered to the faucet at 122°F2.

Water Consuming Systems

Potable water is consumed for the 36 bathroom sinks, 3 kitchen sinks, 38 toilets, and 16 urinals in the building.

There are also 16 water fountains, including 1 in the basement, 7 on the 1st floor, 6 on the 2nd floor, and 2 on the 3rd floor. Additional water is consumed for the cooling tower to offset any evaporated water and drift that occurs during cooling tower operation.

EMS

The HVAC system for the NTF is controlled by a building automation system (BAS) installed by Alabama Controls. The control system can only be accessed from the head end computer for the BAS, located in the basement of the building. The BAS controls both the air side equipment (AHUs and RTUs) and part of the water side equipment (chiller plant), but the boiler plant is not controlled with this system. Only the 3rd floor VAV boxes are controlled by the BAS. Specifically, the following items are on the BAS / EMS:

AHU summary for AHU-1 through AHU-8 (AHU-6 is inactive) Graphical displays for AHU-1 through AHU-5, AHU-7, AHU-8, and the RTU serving the 3rd floor classrooms.

Chilled water plant equipment, which includes 3 chillers, 3 primary pumps (CPP-1 to CPP-3), and the 4 secondary chilled water pumps (CSP-1A, CSP-1B, CSP-2A, and CSP-2B).

Condenser water system, which includes 3 condenser water pumps (CWP-1, CWP-2, and CWP-3) and the 2 cooling tower fans (CT-1 and CT-2).

24 VAV boxes serving the 3rd floor Room level controls for the basement, 1st and 2nd floor

The following equipment is not included in the BAS:

Heating water plant equipment, which includes the 4 condensing boilers, 3 heating water zone pumps, and the primary heating water pump.

Dual duct boxes Exhaust fans and the kitchen hood system 4 of 5 rooftop units and 5 heat pump units Domestic hot water system

Air compressors for pneumatic controls exist in two mechanical rooms; the hot/cold deck AHUs use Barber- Colman pneumatic controls. DDC controls for the chiller plant only; however, the main NTF has pneumatic for the temperature controls and AHU systems. The DDC control for the heating plant is not tied to the central EMS.

Exhibit 9. Example Control Screen for NTF Building

Kitchen Area

At the time of writing this document, the existing kitchen area of NTF is being renovated/expanded (the existing dining area is not included in the scope of the renovation/expansion project). The project is scheduled to be completed March 2019.

All interior walls and finishes will be new. The new kitchen layout will be air conditioned with two new, constant volume, DX, high efficiency packaged rooftop units as well as new makeup air units for required makeup to the new kitchen exhaust hood system. The DX packaged rooftop units will be provided with indirect gas fired heating sections for heat as well as hot gas reheat for facilitation of an active humidity control sequence. The makeup air units will be supply only and will be provided with indirect gas fired heating sections. New, 90% makeup, stainless steel exhaust hoods will be provided with new grease exhaust ductwork and kitchen hood make-up air ductwork. The gas lines serving the existing cooking equipment are to be re-used to the greatest extent possible, but will be modified to incorporate a new cooking equipment arrangement.

The hot and cold water demand for the new kitchen area will be provided by the existing facility system and tapped outside the renovation area (above the hallway ceiling).

LODGING COMPLEX

The lodging complex includes dormitory lodging and administration buildings providing associated support service for students that come to the site for short term training (typically one to two weeks). In addition to 8 active dormitory buildings, the lodging complex also contains an administration office building, laundry, dining facility, and a lounge. A map of the lodging area indicating each building number is shown in Exhibit 10, while Exhibit 11 summarizes building addresses, purpose, and size.

Exhibit 10. Lodging Area Map

Note: Text boxes indicate building numbers for all buildings in the lodging complex. However, buildings 136 and 78 are not included in the audit, and will not be described here.

Exhibit 11. Lodging Area Buildings

Group Building Address Building Use

Floor Space (ft2)

Group 1 Bldg. 320 320 Dekalb Court Administration 4,847 Bldg. 294 294 Dekalb Court Dormitory 30,399

Bldg. 210

Bldg. 320

Bldg. 322

Bldg. 294

Bldg. 28

Bldg. 44

Bldg. 171

Bldg. 277

Bldg. 251

Bldg. 17

Bldg. 19

Bldg. 21

Bldg. 78

Bldg. 136

Bldg. 322 322 Dekalb Court Dormitory 30,399

Group 2 Bldg. 251 251 Straub Circle Lounge 4,847 Bldg. 171 171 Straub Circle Dormitory 30,399 Bldg. 277 277 Straub Circle Dormitory 30,399

Group 3 Bldg. 17 17 Straub Circle Cafeteria 5,629 Bldg. 19 19 Straub Circle Dormitory 30,399 Bldg. 21 21 Straub Circle Dormitory 30,399

Group 4 Bldg. 28 28 Dekalb Court Dormitory 30,399 Bldg. 44 44 Dekalb Court Laundry / Admin 4,847

Group 5

Bldg. 210 210 Dekalb Court Dormitory 30,399 Bldg. 136 136 Dekalb Court Gymnasium 4,847

Bldg. 78 78 Dekalb Court Unoccupied /

Unused 30,399 Bldg. 78 is not in use; however, is maintained to its current state

The lodging area buildings are laid out in subgroups which are indicated in the summary table above. Groups 1, 2, 3, and 5 are arranged with two dorm buildings and one administration building per group. Group 4 is arranged with one dormitory (bldg. 28) and one administrative building (bldg. 44, industrial laundry facility with offices).

These group sets will be used for discussion about the existing conditions at the site. As originally constructed, the groups were set up so that each administration building contained a boiler and chiller that served the dormitory buildings in that group. However, the HVAC system for some groups has been modified during recent renovations, with the installation of individual systems serving each building in the group.

The lodging area buildings were originally designed in 1986 and construction was completed in 1989. Buildings 44, 28 and 210 have undergone major renovations recently, including removal of old boiler/chiller and installation of VRF systems with heat recovery, new instantaneous gas-fired domestic hot water heaters, as well as significant interior upgrades. Major plumbing renovations were also underway for Building 28 during the site visit in October 2017.

There is one guardhouse for the lodging area, which is located near the lodging main entrance in the east section of the complex. It has a total of 125 square feet. The following sections discuss the building construction and envelope, the HVAC systems, the lighting systems, the service hot water heating equipment, water consuming appliances, and the energy management system (EMS).

The dorm occupancy levels are variable depending upon the training needs at any given time. Dorm rooms are typically set up for single occupancy, with a bathroom shared between each set of two rooms. There are 76 to 78 beds per dorm, so full occupancy would include about 540 people in the lodging area. Occupancy levels typically range from approximately 20% to 100% of the maximum throughout the year. Training sessions typically last from one to two weeks.

The building occupancy levels and operating hours for the non-dormitory buildings in the lodging complex vary.

The administration building (320) is occupied 24/7. The lounge (Building 251) is open from 4-10 PM from Sunday-Friday, and from 6 -10 PM on Saturday. The dining facility (Building 17) is open 7 days per week for breakfast from 5:30 AM – 7:30 AM, and for dinner from 5:30 PM – 7:30 PM. At Building 44, the laundry section is occupied from 7:30 AM – 3:30 PM for 6 days per week (Monday-Saturday). The transportation section is occupied from 5:30 AM - 10 PM from Monday-Friday, and 8 hours on Sunday (approx. 2-10 pm).

Building Envelope Each dormitory building is three stories tall, while the administration buildings are all one story. Lodging area buildings are constructed with load-bearing concrete masonry unit (CMU) walls with an air gap. The exterior walls are finished with a brick veneer.

The buildings have sloped roofs with dark brown colored standing metal seam finishing. The roof construction uses wood joists and plywood sheathing. Roofs on most buildings have been replaced within the last 5 years, with the exception of Building 17.

Windows in these buildings were installed in 2008 and have double-glazed panes set in aluminum frames. The windows in the dormitory rooms are operable. The buildings have glass doors for the main entrances, and metal doors for side doors and mechanical rooms.

HVAC Systems

Most of the dormitory buildings have a similar HVAC arrangement, with fan coil units that use chilled water and hot water from the central chiller and boiler plants that serve the set in each group. However, the dormitory buildings that have recently been renovated use different systems, and most of the non-dormitory buildings have separate individual space conditioning equipment. The following paragraphs describe the central heating and cooling plants, followed by the terminal units for the buildings served by those plants.

The chiller located outside the southwest corner of Building 320 provides chilled water for all three Group 1 buildings (dorm buildings 294 and 322, and administration building 320). This unit is a 70-ton air cooled scroll chiller manufactured by Trane in 2015. There is a single primary chilled water pump, which is located in the Building 320 mechanical room. The unit has a 10 HP motor, and does not have a VFD.

Exhibit 12. Building 320 Chiller

The chiller located outside the southeast corner of Building 251 serves the dormitories in Group 2 (buildings 171 and 277). It is a 70-ton air cooled rotary liquid chiller built by Trane in 2007. There is a single primary chilled water pump located in the mechanical room of Building 251. The unit has a 10 HP motor, and does not have a

VFD.

The chiller outside the Northwest corner of Building 17 serves the dormitories in Group 3 (buildings 19 and 21).

The system is a 70-ton air cooled rotary liquid chiller, built by Trane in 2007. There is a single primary chilled water pump located in the mechanical room of Building 17. The unit has a 10 HP motor, and does not have a

VFD.

Heating for the Group 1 buildings (320, 294, and 322) is provided by a single gas-fired horizontal inclined watertube boiler located in Building 320 mechanical room. The Rite Boiler has a rated input of 3,300 MBH (97 BHP). There is a single primary heating water pump, which has a 15 HP motor and does not have a VFD.

Heating for the Group 2 dormitories (buildings 171 and 277) is provided by the 2 gas-fired condensing boilers located in the Building 251 mechanical room. The boilers are both Harsco P-K MACH C-1500 units, with a rated maximum input of 1500 MBH and a 5:1 turndown. The boilers were built 2009. There is a single primary heating water pump, which has a 15 HP motor and does not have a VFD.

Exhibit 13. Building 251 Condensing Boilers

Heating for the Group 3 dormitories (buildings 19 and 21) is provided by 2 gas-fired condensing boilers located in the Building 17 mechanical room. Both boilers are Harsco P-K MACH C-1500 units, with a rated maximum input of 1500 MBH and a 5:1 turndown. The boilers were built 2010. There is a single primary heating water pump, which has a 15 HP motor and does not have a VFD.

Heating and cooling within the individual rooms in the Group 1 and Group 2 dormitories (buildings 294, 322, 171, and 277) is provided by 2-pipe fan coil units (FCUs). These FCUs have not been upgraded since the original construction. Based on the original building drawings, the FCU sizes range from 200-800 cfm, with cooling capacities from 5.8-21.2 MBH, and heating capacities from 4-15 MBH. The FCUs use 3 speed fan motors, with capacities from 1/60 to 1/12 HP (1100, 900, 700 rpm). Switching the dual temperature systems from heating to cooling (and vice versa), are made as needed to meet demand according to annual weather patterns. Regardless of space heating needs, the boilers for these buildings are active year-round as they are used to generate domestic hot water. These four dormitory buildings with 2 pipe FCU systems each have 5 HP booster pumps for the dual temperature system located in the mechanical rooms for each building. None of these pumps have VFDs.

Heating and cooling within the individual rooms in the Group 3 dormitories (buildings 19 and 21) is provided by 4-pipe fan coil units (FCUs). These FCUs were upgraded in 2013. The FCU sizes range from 300-1,000 cfm, with cooling capacities from 8-30 MBH, and heating capacities from 8-22 MBH. The FCU motors are sized at 1/6 to 1/4 HP.

The two dormitory buildings with 4-pipe FCU systems each have 2 booster pumps located in the building mechanical rooms. There is a 10 HP booster pump for heating water, and another 10 HP pump for chilled water.

Both booster pumps are equipped with a VFD.

The conditioned air for Building 320 is provided by one air handling unit (A-38) with a 5 HP fan motor. The AHU has a 1,300 CFM supply fan (270 cfm outside air). It has chilled and hot water coils, and does not have reheat. The AHU supplies conditioned air to the 4 VAV boxes (250-360 cfm per unit) in the building.

The HVAC system for dormitory building 28 was completely renovated in 2016. The original FCUs, exhaust and supply fans, and controls were removed, and a new LG VRF heat pump system with heat recovery was installed.

The system is capable of providing simultaneous heating and cooling to different sections of the building. New FCUs were installed throughout the building. A typical dorm room’s FCU is rated at 440 cfm, with a 7.5 MBH cooling capacity and an 8.5 MBH heating capacity. There are three outdoor units (one for each floor), with a total cooling capacity of 72 tons for the building. The exhaust fans in the attic are equipped with energy recovery ventilator units.

In 2017, the HVAC system for dormitory building 210 was also completely renovated. This building uses the same VRF system equipment as Building 28, including the new FCUs and the outdoor units serving each floor.

The…