FINAL_RCx_Rpt_Dec2016.pdf

MDA / MDH LABORATORY BUILDING

Retro-Commissioning Phase 1: Investigation Final Report State of Minnesota, Department of Administration St. Paul, MN

State Project No. 02LB0017 Sebesta Project No. 220016.00

Sebesta, Inc.

an NV5 Global Company 1450 Energy Park Drive Suite 300 East St. Paul MN 55108 651.634.0775

Final Report

December, 2016

Table of Contents

State Project No. 02LB0017 Sebesta Project No. 220016.00 Page 1 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

Section Page

1.0 Executive Summary

1.1 Recommendations Summary

2.0 Project Team

3.0 RCx Program Schedule

4.0 Energy Use Analysis

5.0 Summary of Existing Systems

5.1 Mechanical Systems

6.0 Investigation Findings

6.1 Building Management System (BMS) Automation System

6.2 Air Handling Units

6.2.1 Penthouse AHUs 1- 6

6.2.2 Ductwork

6.2.3 Lower Level AHU-10

6.3 Laboratory Exhaust Fans

6.4 Chilled Water System

6.5 Hot Water Heating System

6.6 Process Chilled Water

6.7 Lab Support Utilities

6.7.1 Clean Compressed Air (CA):

6.7.2 Process Vacuum (PV):

6.7.3 Acid Neutralization (AW):

6.7.4 Reverse Osmosis / Deionized Water (RO/DI) System:

6.8 Laboratory Air Controller (LAC) Space Lab Air Controls

6.8.1 Device-Level Functional Testing

6.8.2 Integrated System Functional Testing

6.9 Non-Laboratory Space Controls

6.10 BSL3 Agriculture Suites

6.10.1 Visual Inspection of the Architectural Features

6.10.2 Visual Inspection of Directional Airflow

6.10.3 Visual Inspection of Exhaust

6.10.4 Visual Inspection of Supply

6.10.5 Visual Inspection of the BMS

6.11 BSL3 Health Suites

6.11.1 Visual Inspection of the Architectural Features

6.11.2 Visual Inspection of Directional Airflow

6.11.3 Visual Inspection of Exhaust

6.11.4 Visual Inspection of Supply

6.11.5 Visual Inspection of the BMS

6.12 Electrical Systems

6.12.1 Lighting and Lighting Controls

6.12.2 Power and Receptacle Circuiting

6.12.3 Emergency Power Generator

6.12.4 Uninterruptible Power Supply (UPS)

Table of Contents

Sebesta Project No. 220016.00 Page 2 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

7.0 Recommendations for Implementation – Safety Concerns and Energy / Operational Improvement

7.1 Construction Cost Estimate

7.2 Recommendations for Implementation of Solutions

1. Replace 2nd Floor Deteriorated Ductwork:

2. Enhancement of General Lab Exhaust:

3. Update/Repair the Constant Volume Exhaust System:

4. Repair / Replace Existing Equipment:

5. Replace Existing TSI System with New Air Valves:

6. Re-Characterize / Reprogram Existing Lab Air Valves / Control Devices:

7. Agriculture –Third Floor BSL-3 Ag Findings and Recommendations

8. Health –Third Floor BSL-3 Findings and Recommendations

9. Verify Emergency Generator Start-Up Time

10. Electrical Receptacle Circuiting

11. Lighting and Lighting Controls

12. Repair Existing Office VAV Boxes:

13. Replace current slow acting Reheat Control Valves – with 100:1 turndown valves:

14. Modify Humidifiers associated with Air Handling Units (AHU-01 / 06)

15. Upgrade the BMS Graphics for the Strobic Fans (Exhaust)

16. Upgrade the BMS Graphics and the Sensors for AHU-01 / 06 Supply Air

17. Upgrades to the Process Chiller, Control Sequence and Backup Capability

18. Repair / Upgrade Lab Support Utility Systems; Clean Compressed Air (CA), Process Vacuum (PV), Acid Waste (AW), Reverse Osmosis / Deionized Water (RO / DI):

Appendices A: Commissioning Action Matrix (CAM)

B: Cost Estimate Worksheets

C: BSL3 Lab Functional Performance Test Procedures

D: Sketches

E: Electrical Lighting Plans

F: Work Description Worksheets

Executive Summary

Sebesta Project No. 220016.00 Page 3 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

1.0 Executive Summary

Sebesta, Inc. an NV5 Global Company (Sebesta) was selected to provide retro-commissioning services for Minnesota Department of Agriculture/Minnesota Department of Health Lab Building project. The 181,000 square-foot facility was constructed in 2006. Since the building had never been formally commissioned, questions have remained such as “does this building truly work as designed?” and “Are the building systems providing a safe and stable work environment?” The goal was to answer these questions by verifying that the fundamental building systems are operating as required to deliver functional and efficient performance to meet the Owner’s current facility requirements, and the basis of design. The retro-commissioning effort was broken down into two phases in order to complete the work:

the Discovery Phase and the Verification Phase.

The Discovery Phase focused on getting familiar with and increasing our understanding of the original basis of design. Sebesta reviewed existing drawings, specifications, and submittals and compared them to as-built conditions. Sebesta documented programming modifications or operational changes that have been implemented over the life of the facility. We needed to clearly understand the Standard Operating Procedures (SOPs) as they pertain to safety, functionality and energy performance. We met with both the facility maintenance and laboratory supervisors to discuss these requirements. Lastly, we established an understanding of the certification requirements of the building and specifically the specialty spaces (BSL- 3, etc.) as they pertain to Governmental Certification requirements and testing.

During the Verification Phase, our engineers were on site from the beginning of January until June 2016.

We systematically investigated the building from the Penthouse down to the Lower Level. Sebesta focused on the key areas of each floor, by lab and area. Then we investigated the area’s system by system (supply, exhaust, utilities, electrical) down to each terminal device. Once this investigation was complete, we reviewed the system interactions with one another as they affected the building system as a whole. We ran each building system device through its full operational paces in order to identify potential deviations from the original design intent and/or current operational conditions. From this, the Commissioning Action Matrix (CAM) was created to document individual issues. Sebesta included recommendations for improvement measures for each of these issues.

Due primarily to the diligence and dedication of the State’s building operators and staff, the facility has been able to maintain its functionality and operation despite some shortcomings from the original design and construction. However, this project did identify several recommendations that could be implemented to further improve the upon the existing facility performance.

Key Indicators

1. Original Construction Cost (2005): $60M

2. Annual Operating Cost (2015): $1.5M

3. Total pieces of equipment assessed: 1,200+

4. Total issues identified (Mech / Elect): 350 / 350 = 700

5. Projected Construction Cost to Fix: $15M

6. Projected First Cost savings in Energy (15%): $225K

7. Project Annual Savings in Energy (4%): $60K

Executive Summary

Sebesta Project No. 220016.00 Page 4 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

1.1 Recommendations Summary

Due primarily to the diligence and dedication of the State’s building operators and staff, the facility has been able to maintain its functionality and operation despite some shortcomings from the original design and construction. However, this project did identify several recommendations that could be implemented to further improve the upon the existing facility performance. Table 1 identifies the Recommendations for Implementation for addressing the issues discovered during this project.

Table 1 – Recommendations for Implementation In order of Priority

Implementation Recommendations Cost Safety Concern

Operational Efficiency Concern

Mission Critical

Concern 1 Replacing Deteriorated Exhaust Ductwork $1,568,000 x

2 Enhancement of General Exhaust $292,000 x

3 Update/Repair the Constant Volume Exhaust System $197,000 x

4 Repair / Replace Lab Support Equipment $928,000 x x x 5 Replace TSI Pressure System $296,000 x

6 Reprogram Existing (and New) Lab Controllers $255,000 x x 7 BSL-3 AG Improvements $978,000 x 8 BSL-3 Health Improvements $965,000 x

9 Repair Emergency Generator $0 x

10 As-Built and Re-circuit Electrical $555,000 x x

11 Lighting (The Capitol Complex Lighting Standards) $894,000 x

12 Repair Office VAVs $559,000 x

13 Repair Supply VAV/Air Valve Assembly $670,000 x 14 Repair AHU-01 / 06 Humidifier Systems $490,000 x 15 Upgrade the Strobic Fans (Exhaust) - Controls $81,000 x

16 Upgrade the Supply Air Handling Units (AHU-01 / 06) $59,000 x

17 Upgrade the Process Chiller – Controls $69,000 x

18 Repair/Upgrade Lab Support Systems (CA, PV, AW, RO / DW) $106,000 x

19 Building Hot Water HX Controls Upgrade, (Units 1 – 8) $221,000 x

20 Remove and Replace Existing Pneumatic Controllers $296,000 x

21 Upgrade the Penthouse Air Handling Unit (AHU-09) $49,000 x

22 Repair / Upgrade AHU-10 (Lower Level) $89,000 x

23 Replace the point of use UPS with Building wide system $277,000 x

24 Upgrade Existing Lab Pneumatic Air Valves to Electric $4,771,000 x

TOTAL $14,665,000 $6,862,000 $7,710,000 $93,000

Note: As you can see from the ranking of priorities, all of the items that have a safety concern (or Mission Critical) were rated above items that would improve the efficiency and operation of the lab building, The goal of our team is, and will continue to be, to help you regain and maintain the confidence you have in your building. Simply stated, your building will perform and operate in a safe and efficient manner, maximizing the effectiveness of those folks working in the building, and the test results will be validated and accurate, so all of us as tax payers will continue to benefit the value of this very critical building for the State of Minnesota.

Project Team

Sebesta Project No. 220016.00 Page 5 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

2.0 Project Team

Sebesta collaborated with MDA, MDH, and PMD teams for this Retro-commissioning process. The intent of the collaboration was to accomplish the following objectives:

1. Leverage the knowledge and experience of on-site personnel to understand the unique demands of each area of the facility and the cultural implications of current and future operating strategies;

2. Engage on site personnel in changing both equipment and operating strategies that will both better support the MDA and MDH mission in each floor and more effectively manage the cost and resource consumption required to support that mission;

3. Provide a mechanism to understand the current state of knowledge and expertise within the O&M team and to improve their expertise through collaboration and,

4. Engage the O&M team in the process of improving equipment and strategies to assure that changes made in operating and maintenance strategies are fully embraced by this team.

The Retro-Commissioning Team included:

Name Position/Title/Role Email Dept.

Sebesta

Dave Harrison Sebesta PM dharrison@sebesta.com Sebesta Theresa Warner Sebesta Assistant PM twarner@sebesta.com Sebesta Carol Donavan Sebesta Lead BSL3 Engineer cdonovan@sebesta.com Sebesta Matt McReynolds Sebesta Lead Mechanical Engineer mmcreynolds@sebesta.com Sebesta Robert Noe Sebesta RCx Lead Onsite CxA rnoe@sebesta.com Sebesta Tom King Sebesta RCx Onsite CxA tking@sebesta.com Sebesta Barry Bridges Sebesta RCx Onsite CxA bbridges@sebesta.com Sebesta Jamie Olivas Sebesta Electrical/Olivas Consulting jaimeo@olivasconsulting.com Olivas Mary Horgan Sebesta Electrical/Olivas Consulting maryh@olivasconsulting.com Olivas Allan Holm Sebesta/Electrician al@mayerelectriccorp.com Mayer James Noe NCS/Sebesta ncservices@charter.net NCS Wayne Beierman Sebesta CxA Electrical WBeierman@Sebesta.com Sebesta James Schultz Honeywell Direct – Project PM James.Schulz@Honeywell.com Honeywell Tom Healy Honeywell Direct – PM Thomas.Healy@Honeywell.com Honeywell Mark Wolle Honeywell Direct Mark.Wolle@Honeywell.com Honeywell Kyle Schmidt Honeywell Direct Kyle.Schmidt@Honeywell.com Honeywell Department of Administration

Christopher A Guevin Plant Management Division Director chris.guevin@state.mn.us Admin / PMD

Gene M Peterman Building Manager gene.peterman@state.mn.us Admin / PMD

Bruce Dzieweczynski Building Maintenance Coord bruce.dzieweczynski@state.mn.us Admin / PMD

Jerry McDougle Plant Mntc Engineer Chief jerry.mcdougle@state.mn.us Admin / PMD

Bill Devore Plant Mntc Engineer bill.devore@state.mn.us Admin / PMD

Ryan Allen Principal Project Manager ryan.allen@state.mn.us Admin / RECS

Scott Miron Automation Systems Supervisor scott.miron@state.mn.us MN.IT /Admin

David Dahlin Plant Mgmt – Chief Engineer David.Dahlin@state.mn.us Admin / PMD

Guy Cooper PMD Electrical Supervisor Guy.Cooper@state.mn.us Admin / PMD

Gary Swanson PMD-Electrical Gary.M.Swanson@state.mn.us Admin / PMD

Chad Olson Plant Operations Manager Chad.olson@state.mn.us Admin / PMD mailto:James.Schulz@Honeywell.com mailto:chris.guevin@state.mn.us mailto:gene.peterman@state.mn.us mailto:bruce.dzieweczynski@state.mn.us mailto:jerry.mcdougle@state.mn.us mailto:bill.devore@state.mn.us mailto:ryan.allen@state.mn.us mailto:scott.miron@state.mn.us

Project Team

Sebesta Project No. 220016.00 Page 6 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

Name Position/Title/Role Email Dept.

Department of Agricultural

Gary Horvath Lab Director gary.horvath@state.mn.us Ag

Lisa Buhl Operations Unit Supervisor elisa.buhl@state.mn.us Ag

Bryanne Shaw Biology Section Manager bryanne.shaw@state.mn.us Ag

Tina Seeland Plant Analysis Unit Supervisor tina.seeland@state.mn.us Ag

Matthew Forstner Microbiology Unit Supervisor matthew.forstner@state.mn.us Ag

Michelle Campbell Chemistry Section Manager michelle.campbell@state.mn.us Ag

Treeske Ehresmann Food Chem/Toxicology Unit Sup. Treeske.Ehresmann@state.mn.us Ag

Yoko Johnson Environmental Analysis Unit Sup. yoko.johnson@state.mn.us Ag

Kathryn M Reynolds Water Analysis Unit Supervisor kathryn.reynolds@state.mn.us Ag

Doug Buhl MDA Facilities Manager doug.buhl@state.mn.us Ag

Department of Health

Facilities

Abigail Mosher Agency Chief Financial Officer abigail.mosher@state.mn.us Health

Virginia Davis Facilities and Finance Asst. Div Dir virginia.davis@state.mn.us Health

Kent Konecny Building Operations Supervisor kent.konecny@state.mn.us Health

Kevin Umidon FFM Kevin.umidon@state.mn.us Health

Lab Management

Joanne Bartkus PHL Division Director Joanne.Bartkus@state.mn.us Health

Myra Kunas PHL Assistant Division Dir Myra.Kunas@state.mn.us Health

Dan Hammersley Quality Assurance & Safety dan.hammersley@state.mn.us Health

Clinical Lab

Sara Vetter Clinical Laboratory Director Sara.Vetter@state.mn.us Health

Maureen Sullivan Emerg Preparedness Resp Unit S Maureen.Sullivan@state.mn.us Health

Paula Vagnone Microbiology Supervisor Paula.Snippes@state.mn.us Health

David Boxrud Molecular Epidemiology Sup Dave.Boxrud@state.mn.us Health

Anna Strain Virology Supervisor Anna.Strain@state.mn.us Health

Sharon Pendergrass Infectious Disease Op Sup Sharon.Pendergrass@state.mn.us Health

Environmental Lab

Paul Moyer Environmental Laboratory Mgr Paul.Moyer@state.mn.us Health

Ron Brown Env Sample Receiving Unit Sup Ron.Brown@state.mn.us Health

Cori Huffman Operations Unit Sup Cori.Huffman@state.mn.us Health

Jeffrey Brenner Inorganic Chemistry Sup Jeffrey.Brenner@state.mn.us Health

Stephanie Drier Organic Chemistry Supervisor Health

Stefan Saravia Biomon & Emerg Contaminant Sup Stefan.Saravia@state.mn.us Health

Newborn Screening Lab

Mark McCann Newborn Screening Manager Mark.McCann@state.mn.us Health

Amy Hietala Newborn Screening Lab Supv Amy.Hietala@state.mn.us Health

Amy Gaviglio Newborn Screening FolUp Supv Amy.Gaviglio@state.mn.us Health

Patricia Constant Newborn Screening Comm Edu Patti.Constant@state.mn.us Health

Jill Simonetti Newborn Screening Op Sup Jill.Simonetti@state.mn.us Health mailto:gary.horvath@state.mn.us mailto:elisa.buhl@state.mn.us mailto:bryanne.shaw@state.mn.us mailto:tina.seeland@state.mn.us mailto:matthew.forstner@state.mn.us mailto:michelle.campbell@state.mn.us mailto:Treeske.Ehresmann@state.mn.us mailto:yoko.johnson@state.mn.us mailto:kathryn.reynolds@state.mn.us mailto:doug.buhl@state.mn.us mailto:abigail.mosher@state.mn.us mailto:virginia.davis@state.mn.us mailto:kent.konecny@state.mn.us mailto:Joanne.Bartkus@state.mn.us mailto:Myra.Kunas@state.mn.us mailto:dan.hammersley@state.mn.us mailto:Sara.Vetter@state.mn.us mailto:Maureen.Sullivan@state.mn.us mailto:Paula.Snippes@state.mn.us mailto:Dave.Boxrud@state.mn.us mailto:Anna.Strain@state.mn.us mailto:Sharon.Pendergrass@state.mn.us mailto:Paul.Moyer@state.mn.us mailto:Ron.Brown@state.mn.us mailto:Cori.Huffman@state.mn.us mailto:Jeffrey.Brenner@state.mn.us mailto:Stefan.Saravia@state.mn.us mailto:Mark.McCann@state.mn.us mailto:Amy.Hietala@state.mn.us mailto:Amy.Gaviglio@state.mn.us mailto:Patti.Constant@state.mn.us mailto:Jill.Simonetti@state.mn.us

RCx Program Schedule

Sebesta Project No. 220016.00 Page 7 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

3.0 RCx Program Schedule

The MDA/MDH Lab Project is divided into the following four phases:

Phase 1: Retro-commissioning

Phase 2: Design

Phase 3: Installation

Phase 4: Validation

The program schedule is included on the next page to illustrate the timeline of events for all four phases.

RCx Program Schedule

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Phase One – Investigation

PAGE INTENTIONALLY LEFT BLANK

ID Task Name Start Finish

1 State of Minnesota MDH / MDA RCxA Tue 1/19/16 Wed 8/14/19

2 Phase 1 Retro-commissioning Tue 1/19/16 Fri 12/9/16

3 Verification Tue 1/19/16 Mon 6/13/16

4 Penthouse Testing Tue 1/19/16 Fri 1/29/16

12 Second Floor Testing Tue 2/2/16 Fri 3/18/16

187 First Floor Testing Tue 3/22/16 Mon 4/11/16

395 Lower Level Testing Mon 4/11/16 Fri 4/15/16

417 3rd Floor Testing Tue 4/19/16 Mon 5/16/16

626 Building Wide System Testing Tue 5/17/16 Mon 5/30/16

629 Summer Seasonal Testing Tue 6/7/16 Mon 6/13/16

632 Report Review Meeting Thu 10/6/16 Thu 10/6/16

633 Final Report Thu 10/20/16 Fri 12/9/16

634 Phase 2 - Design Wed 12/14/16 Fri 8/11/17

635 Schematic Design (SD) Wed 12/14/16 Mon 2/13/17

636 Design Development (DD) Tue 2/14/17 Thu 5/11/17

637 Construction Documents (CD) Fri 5/12/17 Fri 8/11/17

638 Bidding and Award Mon 8/14/17 Thu 10/12/17

639 Phase 3 - Implementation / Construction Fri 10/13/17 Tue 11/13/18

640 Phase 4 – Validation (Cx) Mon 10/15/18 Wed 8/14/19

642 Winter Fixes Schedule: Tue 7/12/16 Fri 10/28/16

643 100% Bid Docs publicly posted Tue 7/12/16 Tue 7/12/16

644 Addendum posted Mon 7/25/16 Mon 7/25/16

645 Bid Opening Thu 7/28/16 Thu 7/28/16

646 Award notice to contractor (Versacon Inc) Thu 8/18/16 Thu 8/18/16

647 Submittal review start Mon 8/29/16 Tue 9/6/16

648 Construction substantial completion Thu 10/27/16 Fri 10/28/16

Jan Mar May Jul Sep Nov Jan Mar May Jul Sep Nov Jan Mar May Jul Sep Nov Jan Mar May Jul 2016 2017 2018 2019

Task

Split

Milestone

Summary

Project Summary

Inactive Task

Inactive Milestone

Inactive Summary

Manual Task

Duration-only

Manual Summary Rollup

Manual Summary

Start-only

Finish-only

External Tasks

External Milestone

Deadline

Progress

Manual Progress

Minnesota Dept of Admin.

MDA / MDH Lab Building RCX

Schedule

Project: State of MN RCxA_TAW_ Date: Wed 12/21/16

Energy Use Analysis

Sebesta Project No. 220016.00 Page 9 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Phase One – Investigation

4.0 Energy Use Analysis

Although the key initiative of this project was to regain the confidence level of your building from a safety first point of view, a good portion of the recommendations proposed in this report could potentially improve the operation and energy efficiency of the overall building.

The utility consumption data for calendar year 2008 through calendar year 2015 are illustrated in the tables below. During this time period, the average use (in kbtu/sf) approximately was 349. According to the Labs21 data, the average energy use for a laboratory building of similar use in the Midwest is approximately 360 kbtu/sf. The full Labs21 dataset can also be found in Table 4 below. Other than CY2015, the lab building performed better than peer facilities.

Table 2 - Historical Engery Consumption

Table 3 - Annual Consumption by Utility

Energy Use Analysis

Sebesta Project No. 220016.00 Page 10 MDA/MDH Lab RCx December 2016 Retro-Commissioning Final Report ©2016 Sebesta, Inc.

Table 4 - Labs21 Comparative Data

Summary of Existing Systems

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Phase One – Investigation

5.0 Summary of Existing Systems

MDA/MDH Lab Building is approximately 181,000 square foot and was constructed in 2006. The project consisted of commissioning the following systems:

5.1 Mechanical Systems

- Ten total air handling units are located in the building.

o Nine are located in the penthouse. Of the nine units, six are the large main, built-up units supplying air to the labs. These are 100% outside air units with heat recovery wheels. Two units are dedicated to the avian specialty lab. One constant volume unit serves the penthouse area.

o One unit is located on the lower level and serves the mechanical and electrical utility rooms. The unit is constant volume.

- Exhaust Fans o A total of 12 exhaust fans (EF-1A/B thru EF-6A/B) serve the lab floors. The fans are arranged in pairs for a lead/lag operation. These fans pull air through the energy recovery wheel for the main air handling units described above.

o The BSL-3 Ag area is served by a pair of exhaust fans (EF-7A/B) with a bag in/bag out filter assembly.

o The BSL-3 Health area is served by a pair of exhaust fans (EF-9A/B) with a bag in/bag out filter assembly.

o The unknown accessioning area with the BSL-4 Glovebox is served by a pair of exhaust fans (EF-10A/B) with a bag in/bag out filter assembly.

o There are three exhaust fans on the first floor serving the loading dock, storage and refuge areas.

- Lab Air Controller (LAC) Air Valves o There are a total of 158 supply air venturi valves and 278 exhaust air venturi valves serving the laboratory areas, BSL-3 suites, lab storage areas, and corridors. There are approximately 162 fume hood and bio safety cabinets located in the laboratory areas. The floor by floor breakdown is as follows:

The first floor has 37 supply air valves and 58 exhaust air valves.

The second floor has 57 supply air valves and 137 exhaust air valves.

The third floor has 64 supply air valves and 83 exhaust air valves.

- TSI Space Pressure Control o There are total of 17 TSI controllers located on the first, second, third floors and penthouse. The controllers for the lab floors are connected to exhaust dampers on the exhaust main that will pull air from the office area to maintain the labs at negative pressure. There are two sensors per floor, one on each side of the building. The three penthouse TSIs maintain the lobby static pressure to keep the building from over or under pressurizing. The static pressure reference is located in the lobby.

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Phase One – Investigation

- Office Variable Air Volume Boxes o There are 110 VAV boxes located on the lower lever through 3rd floor serving the office areas, conference rooms, storage areas, IT closets, and restrooms.

o In addition to the VAVs in the office areas and conference rooms, fin tube and radiant hot water ceiling panels are located along the windows to compensate for building skin losses.

- Process Chilled Water o The process chilled water system serves to cool critical cooling areas of the building that require year round cooling. There are approximately 12 fan coil units and small air handling units connected to the chilled water system. There are two pumps: one pump flows through the dry coolers for winter operation and the other pump flows through the chiller for summer operation.

- Capitol Complex Chilled Water o Chilled water for the air handling units is provided from the Capitol Complex energy loop. Three chilled water pumps boost the pressure from district and flow through the cooling coils in the AHUs in the penthouse and lower level.

- District Energy Hot Water o The main hot water for the air handling units, terminal units, and reheat coils is generated from eight water-to-water heat exchangers and circulated using four hot water heating pumps. District Energy supplies 240°F water to the heat exchanger and sends out 180°F to 140°F water to the building. Water temperature is reset based on outside air temperature.

o A second heating loop serves the air handling unit pre-heat coils. This system operates in during the cold weather only. The system circulates glycol solution to bring the entering air temperature to the units up from outside temperature to +5°F. Two heat exchangers and two pumps make up the 50% glycol solution system.

- Building Automation System or Building Management System o The Honeywell building automation system (BMS) is responsible for operating all the building’s mechanical systems except for the lab spaces, which are controlled by the Phoenix system (Lab Air Controller – LAC). This system provides the automation programming, monitoring, trending, and alarming that one can expect from a modern BMS. The Honeywell EBI system is the graphical interface, or front-end, to the BMS used to monitor the systems and manipulate set points.

o The Lab Air Controller (LAC) control system is responsible for controlling the laboratory supply air and exhaust air venturi valves. The system is controlled separately from the Building Management (BMS) system. Lab device information such as air flows, alarms, sash positions, etc. are available (read only) at the BMS.

- Lab Support Utilities o Lab owned equipment was reviewed and is included in this report as follows:

Vacuum System

Acid Neutralizer

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Phase One – Investigation

Clean Compressed Air

Reverse Osmosis / Deionized Water (ROW / DIW) System

- Miscellaneous Mechanical Systems o There is one dust collector located on the penthouse roof level that is exhaust air from the feed grinding hood located on the second floor agriculture lab.

o There are three exhaust fans serving the toilet rooms and chemical storage.

o Domestic Hot Water Heaters and Circulating Pumps (not part of Assessment) o Process Steam Boilers and associated equipment (not part of Assessment) o Building control pneumatic air is from a packaged air compressor located in the mechanical room on the lower level.

o Gas-fired steam humidifiers for each air handling unit are located in the penthouse adjacent to the unit served.

o There are seven cabinet unit heaters located in stair wells and vestibules.

o There are five unit heaters located in the loading dock and penthouse.

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Investigation Findings

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Phase One – Investigation

6.0 Investigation Findings

The below sections describe the system and the issues we found as a result of this investigation. This is not a full list of all the issues

6.1 Building Management System (BMS) Automation System

Comprehensive functional performance testing of the building systems required simulating conditions through set point manipulation and then observing the system’s response. This response should line up with what is documented in the sequence of operation as-builts. We found most systems control to the as-builts; however, there are instances where the desired response did not occur. Typically this happened when a BMS point was manually overridden or the sequence was modified to optimize equipment operation for one particular condition, so it no longer matched the as-built sequence.

Note: It needs to be clarified, that when we tested the BMS system, we measured our results against the original design parameters (temperature set points, flowrates, etc.) so while in many cases we did not see the desired results (original design intent), that does not mean the BMS is not operating correctly, rather, more likely it confirms that the original design parameters have been modified, i.e.

the BMS system has been adjusted to meet the new load / space requirements (temperature set points, flowrates, etc.). Therefore, many of the negative results documented, are not issues, but rather a response to an adjustment made. Going forward, the intent is to update the sequences / set points (as applicable) so the current design requirements are in place within the BMS program.

For the few points that were overridden, the general operation of the equipment is required over precise functionality. This was evident during AHU humidifier testing. Some humidifiers were not humidifying despite a call for humidification. As a result, these humidifiers were manually overridden to be enabled, thus removing some of the automatic abilities of the control system.

Some sequences of operation have been modified by PMD to achieve optimal equipment performance for actual conditions rather than what was outlined in the original design. Sebesta found this during testing of the hot water system and process chilled water system. The heat exchanger sequencing was modified for better supply water temperature control. For the process chilled water, the outside air switchover temperature set point (dry cooler to chiller switchover) was increased from the original set point to allow for more reliable chiller operation. See sections below for more information on these issues. In both cases, the changes should be documented as improved set points from an operational standpoint, and kept as a reference for building operations personnel.

The other issue affecting the Building Management System (BMS) is graphical errors. These range from incorrect equipment configurations to misleading set point values. For example, on all of the AHUs, there is an integral face and bypass hot water coil that is depicted incorrectly (Figure 1). The graphics depict an air path that bypasses the hot water coil and two chilled water coils completely, when in actuality, only the hot water coil is bypassed.

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Figure 1 - BMS Graphical Error

Other errors include backwards heat recovery wheel pressure reference locations and final filters graphics that are non-existent on AHUs 9 and 10. Some graphics have set points that are misleading. For example AHU-9 has what appears to be a discharge temperature set point located right above the current discharge air temperature (Figure 2). It is not evident that this is actually a low limit set point rather than a set point to control the heating/cooling coils. Other equipment graphics have a (downwards arrow) symbol to indicate these lower limit points.

Figure 2 - Misleading Setpoint

In general, the Building Management System (BMS) air handler graphics are overly detailed and difficult to follow in some cases. There are three modes of control for the exhaust fans: primary, secondary, and tertiary. The BMS will activate one of these modes to either maintain static pressures at the spaces or maintain a set point to protect ductwork. The primary control is responsible for maintaining the exhaust static pressures referenced in six areas of the building. Generally the exhaust needs to be above 1” wg for the exhaust air valves to work correctly. The secondary and tertiary control modes are responsible for preventing over-pressurization in different parts of the ductwork in the penthouse. The graphics do not clearly indicate the active control mode. This requires the building operator to have knowledge of three levels of control, as the as-built sequences of operation do not detail the exhaust operation at this level of control.

When graphics include the wrong information or becomes lost in a screen full of data, it confuses building operators and consultants. A full list of BMS graphic improvements and graphical errors are included in the CAM (Appendix A).

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Phase One – Investigation

6.2 Air Handling Units

6.2.1 Penthouse AHUs 1- 6

These large, once-through air handlers serve ventilation air to the labs and offices. All six units are headered together controlling to maintain a common supply and exhaust duct static pressure set point. Each unit is paired with two parallel-operating Strobic exhaust fans. There are four supply pressure reference points and six exhaust pressure reference points located throughout the building.

The 100% outside air units use reclaimed energy from the heat recovery wheels to temper the outside air. Outside air is first preheated by a hot water coil, goes through the heat recovery wheel, further heated to discharge air temperature set point through an integral face and bypass hot water coil, passes through two sets of chilled water coils, and is humidified on the supply air side. The exhaust side consists of the heat wheel, and the two exhaust fans. There are heat wheel bypass dampers located on AHU-1, 3, and 5 only.

Overall the AHUs and EFs control properly. The system provides sufficient static pressure to allow the lab air valves to work properly. As for temperature control, the units were found controlling to the wrong humidification set point during the seasonal testing, but after this was corrected, the units provide stable discharge air temperatures. Space temperature problems within the office and lab spaces stem from failed reheat actuators or improperly controlling VAVs.

The problems affecting the AHUs and EFs performance are primarily maintenance related. The most common problem was out of calibration temperature and pressure sensors. Other problems include low space relative humidity levels because humidifiers are down for repairs or have humidity sensors that are out of calibration. Figures 3 and 4 show other maintenance related problems. In Figure 3, AHU-5’s heat recovery wheel was significantly damaged when the wiper dug into the wheel media. There is an ongoing PMD project to replace damaged heat wheels, but the wheels will always be susceptible to damage due to the fragile media. In Figure 4, the supply fan flex connection has ripped allowing air to short circuit.

Freezing of heating and cooling coils has been an ongoing problem. Figure 5 shows a portion of a cooling coil that froze and the resulting fix. PMD has been proactive in draining the cooling coils

Figure 3 - AHU-5 Heat Recovery Wheel Damage

Figure 4 - Ripped Flex Connection at AHU-3 Supply Fan

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Phase One – Investigation during winter, but the heating coils continue to be at risk to freezing. A section of AHU-4’s heating coil froze due to poor placement of the averaging temperature sensor from the heat recovery wheel outlet. A Sebesta Winter Fix project is currently in place to increase the sensor coverage for all AHUs. (See Section 6.0, recommendation S8 for details of this project).

There are unreliable pneumatically controlled devices on the AHUs and EFs: the integral face and bypass (IFB) dampers on the heating coil and the outside air bypass dampers on the exhaust fans. While the IFB damper controls properly, the exhaust outside air damper has failed to open on very cold winter days thus disabling the associated AHU. It appears the pneumatic lines are freezing which inhibits the actuation. In both cases, the pneumatics should be replaced with electronical actuators for precision and reliability. This also being corrected in the Winter Fix project.

6.2.2 Ductwork

The condition of the ductwork was assessed during investigation. Corrosion developing on galvanized exhaust ductwork is a known problem, and a previous project addressed some of the corroded ductwork by replacing and patching sections. We found more sections on the second floor labs that use corrosive acids. While there is stainless steel ductwork connected to fume hoods, the duct eventually connects to galvanized exhaust mains that cannot handle acids. Highly corrosive particulates within the exhaust air stream fall out of suspension at or near the transitions from branch ductwork to the mains. At these locations, the velocity of the air is significantly slower due to the large change in duct size. This can be seen in Figure 6 in Lab 255.

Other sections of corrosion were found on galvanized branch ductwork where stainless should have been used. Figure 7 shows extensive damage to the exhaust ductwork from a connected snorkel in Lab 254 acid lab.

Figure 5 - AHU-6 Repaired Cooling Coil Section

Figure 6 – L255 Corrosion Forming at Stainless to Galvanized

Connection

Figure 7 – L254 Corrosion on Galvanized Ductwork

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Phase One – Investigation

In addition to the corroded ductwork, Sebesta discovered open-ended ducts not extending below the ceiling tiles on the exhaust ductwork. These ducts were originally intended, per design, to be connected to point-of-use devices in the lab as part of the constant-volume exhaust system. In Figure 8, two open-ended ducts can be seen with their dampers open. It is unnecessary to exhaust from the ceiling space. The ducts should be capped if not used as intended.

6.2.3 Lower Level AHU-10

One air handler provides ventilation air to the mechanical and electrical rooms located in the basement. This built up unit maintains space temperature in each room. In addition to the heating coil in the unit, each room branch has a reheat coil to maintain space temperature set point. The unit has return air and provides a minimum outside air percentage when not economizing.

Overall, the unit maintains the required space temperature. The main issue with the unit is the heating coil appears to not be required to maintain space temperature. The mixed air temperature is such that when the space requires heating the duct mounted heating coils can maintain the space temperature well within the requirements. In addition, both spaces have high heat loads and rarely require heat. As a consideration for the design phase, removing the heating coil could reduce a pressure drop in the system, and eliminate a potential point of system failure.

6.3 Laboratory Exhaust Fans

The non-BSL3 laboratory exhaust fans, or Strobic exhaust fans, are interlocked with the operation of the building AHUs. AHU-1 thru 6 are each paired with two parallel-operating exhaust fans. Aside from failing pneumatically controlled outside air dampers, these unit overall control and work properly. On cold, winter mornings, the outside air damper pneumatic lines are susceptible to freezing causing the corresponding AHU to be taken down until the dampers can modulate freely again. These actuators are scheduled to be replaced with electronic in a separate project performed by Sebesta (see Section 6.0, recommendation S8 for details of this project).

6.4 Chilled Water System

Chilled water is provided by the Capitol Complex chilled water plant. Three chilled water control valves modulate to maintain the chilled water return temperature set point. These valves are pneumatically controlled but are still functional and control properly. The chilled water BTU (energy) meter no longer communicates to the BMS. With less system efficiency data from the BTU meter, system performance is analyzed through trending of differential pressures and supply/return water temperatures.

The three variable-volume chilled water pumps (P-4, 5, and 6) were designed to be sequenced to maintain the chilled water load; however, during system testing, the standby pumps failed to start when the differential pressure set point could not be achieved. Honeywell reviewed the logic and found that the programming was incomplete and only allowed one pump to run regardless of cooling load. This was corrected during the investigation. The chilled water system is capable of meeting the largest cooling loads with a single pump, thus minimizing the impact of the incomplete controls programming had on the system.

Figure 8 - Open-Ended Ductwork

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Phase One – Investigation

6.5 Hot Water Heating System

District Energy supplies high temperature hot water to eight heat exchangers. The building hot water passes through the load side of the heat exchanger, and is then distributed throughout the building. The original design of the system intended to have the heat exchangers sequenced in progression to maintain supply water temperature set point, but the sequence has been modified to better meet the demand of the building. Currently four heat exchangers modulate in parallel to maintain the supply water temperature set point. The heat exchangers are rotated based on runtime hours.

The hot water pumping system includes four variable-volume pumps (P-7, 8, 9, and 20) sequenced in unison to maintain the differential pressure set point. The pumps stage and control properly. When testing pump failures for lead/lag operation, the lag pump started after the lead pump failed, but the third (standby) pump did not start after the new lead pump failed. It was discovered that the failures activated latching alarms, which requires manually resetting at the EBI. The third standby pump will not start until the latching alarms are acknowledged by an operator. It is not clear from the front-end graphics that this procedure needs to be performed, which if not followed has the potential for the building to lose heating hot water should two pumps fail.

6.6 Process Chilled Water

The process chilled water provides year-round cooling to critical rooms and equipment throughout the building. This system includes an air-cooled chiller that operates when outside air temperatures are above 46°F, and two dry coolers that operate when temperatures are below 46°F. During testing of the system, Sebesta found a number of design and controls deficiencies.

The current pumping system has one pump for the dry coolers and one pump for the chiller. The pumps are not headered together (schematic provided below). With this configuration, there is no redundancy is this system. Enabling the other system if a pump fails is not possible due to outside air conditions affecting the operation and temperature of the chilled water. Rooms and equipment served by the process chilled water will fail in the event of a failure of either pump.

Figure 9 - Process Chilled Water Schematic

The chiller/dry cooler switchover set point has been adjusted by facilities management from the original sequence of operation. The original sequence calls for the dry coolers to operate when the outside air temperature is 30°F and below, and when 35°F and above, the chiller is enabled. Now the system will change over at a 46°F outside air temperature set point due to equipment issues at cooler temperatures.

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Phase One – Investigation

There is to be no simultaneous operation of both systems. Because the switchover set point was increased over the original design to achieve general equipment operation in lieu of precise functionality, operational efficiencies are reduced and may result in short cycling and unpredictable control.

The pumps are fitted with VFDs but operate as constant volume. An energy opportunity includes modulating the dry-cooler pump speed to take advantage of partial loads. Another opportunity to further investigate would be to modify the control to stage the dry coolers and fans instead of the current lead/lag operation.

6.7 Lab Support Utilities

The lab support utilities include the following; clean compressed air, process vacuum, acid neutralization and RO/DI Water.

6.7.1 Clean Compressed Air (CA):

System consist of two (2) Atlas Copco ZT-18 Oil-Free Compressors, one (1) vertical air receiver, twin desiccant dryers (CT-65) and Filters ( 1 pre-filter and 2 post-filters). All of the equipment is located in the lower level. System is set up to run lead / lag, maintaining a constant pressure of at least 115 psig in the piping system (Designed for 125 psig). All piping is copper and sized for the capacity of the system. Run hours, loaded hours and motor starts on the equipment has been equally spilt between the 2 units. The desiccant dryers maintain a clean dry continuous flow of compressed air at -30°DPD, 72°F, 0.1 micron.

Analysis of the motor starts (which average 50 times / day) and the run hours, the compressors are running unloaded quite a bit, suggesting they are oversized for the application.

Recommendation would be to look at downsizing at the end of their useful life (air-side) or add a small trim compressor.

Current Condition Excellent

Life Expectancy Compressors 70% life remains, Dryers 20% life remains

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Phase One – Investigation

6.7.2 Process Vacuum (PV):

System consist of two (2) Squire-Cogswell Aeros liquid ring vacuum pumps, with the associated separators, air-cooler, surge tank and silencers. All of the equipment is located in the lower level.

System is set up to run lead / lag, maintaining a constant vacuum of 25 in hg in the piping system (Designed for 28 in hg). All vacuum piping is copper and sized for the capacity of the system. Run hours, on the equipment has been equally spilt between the 2 units. The discharge piping is galvanized steel.

Analysis of the run hours, the pump bearings have about 76% life remaining. Recommendation would be to continue a strong ongoing maintenance program, looking at the bearings, cleaning the radiators, checking the liquid levels and inspecting the silencers.

Current Condition Excellent

Life Expectancy Pumps 76% life remains

6.7.3 Acid Neutralization (AW):

System consist of one (1) solids inceptor, and one (1) acid neutralization tank (filled with limestone chips. All of the equipment is located in the lower level. System is set up to run as a gravity, flow through. All lab waste piping is polypropylene and sized for the capacity of the system. Discharge (neutralized) piping is cast iron.

Current Condition Excellent

Life Expectancy Could not determine the remaining life expectancy of the limestone chips

Analysis of the physical condition of the system, shows all components in excellent working order, it is unclear of the life expectancy of the limestone chips, but expect they are due for replacement, finally it is recommended that the tank area be updated to provide containment protection against a tank / pipe failure.

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6.7.4 Reverse Osmosis / Deionized Water

(RO/DI) System:

Overall the RO / DI system is in good working order, and it providing quality water at the required flowrate.

As with any high pressure system, there are minor issues with fittings and inline devices.

The issue under review was to determine cause of intermittent damage to piping connections resulting in RO/DI Leaks. There have been about seven leaks in the 11 years of service, with one event caused by a damaged check valve. Except for one early leak at the point where city water connects to the system, the leaks have been after the RO storage tank outlet of the DI system distribution pump. Leaks are typically during unoccupied hours and even a small leak over time becomes a “flood.” These floods invariably require a shutdown of the system eliminating the availability of RO/DI water in the labs. There is no logging (recorded history) by the RO/DI controller of pressure, flow, or water quality. Furthermore there is no interface between the RO/DI controller and BMS.

The RO sub-system high pressure pump cycles on and off as demand uses RO/DI water, but is hydraulically separated from the DI sub-system by a large RO water storage tank. It is unlikely that the on/off cycle of the RO pump causes the leaks observed in the DI sub-system.

This special packaged “skid” was not in the mechanical or plumbing drawings for the building construction. A submittal for installation was not found in O&M manuals during our review.

The following are observations about the system:

1. The pattern of leaking is spread over several years and becomes significant in a short time. The piping material and gaskets are expected to fail slowly with some initial weeping if the problem is deterioration from age. Building M&O did not report seeing deteriorated material. The fault seemed to be a single event.

2. The second pump in the system provides circulation through the RO tanks and distribution into the building. Its suction head appears based on the atmospheric head of the RO storage tank. With the tank at low level (four feet) and a high demand it is possible that the inlet to the distribution pump drops below the required net positive suction head of the pump causing cavitation and slugging flow.

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Phase One – Investigation

3. A short duration power bump may cause the second distribution pump to stop, and then with its across-the-line starter, create a water hammer event.

4. The Tank Manufacturer literature indicates that between…