Basis of Design_for reference only.pdf

BASIS OF DESIGN

DECENTRALIZE STEAM

AT NAVAL HEALTH CARE CLINIC

BID DOCS SUBMISSION

NHCNE Naval Complex Newport, RI

12/30/2019

PREPARED BY

KUEGLER ASSOCIATES

consulting engineers 51 Depot St, Suite 104, Watertown, CT 06795

ENVIROMED SERVICES, INC.

470 MURDOCK AVENUE

MERIDEN, CT 06450

DIVERSIFIED TECHNOLOGIES CONSULTANTS

2321 WHITNEY AVENUE

HAMDEN, CT 06518

JOHN SMOLEN & ASSOCIATES

50 DEVINE STREET, UNIT A

NORTH HAVEN, CT 06473

TABLE OF CONTENTS

1 SCOPE 3

2 ENVIRONMENTAL 3

2.1 EXISTING CONDITIONS

2.2 RECOMMENDATIONS

3 CIVIL 4

4 ARCHITECTURAL AND STRUCTURAL 4

5 MECHANICAL 5

5.1 MECHANICAL CODES & STANDARDS

5.2 EXISTING STEAM SYSTEMS AND CONDITIONS

5.2.1 BUILDING A6

5.2.2 BUILDING 23A

5.2.3 BUILDING 43

5.2.4 BUILDING 44

5.2.5 BUILDING 49

5.3 PROPOSED MECHANICAL SYSTEMS

5.3.1 GENERAL DESIGN CONSIDERATIONS

5.3.1.1 GAS SYSTEMS

5.3.1.2 CONTROLS

5.3.2 BUILDING A6

5.3.3 BUILDING 23A

5.3.4 BUILDING 43

5.3.5 BUILDING 44

5.3.6 BUILDING 49

6 APPENDIX

6.1 PROPOSED EQUIPMENT

1 SCOPE

The scope for the Decentralize Boiler Plant A6 project includes an investigation and analysis for decentralization of the existing steam infrastructure at Naval Health Clinic New England. The boiler plant housed in Building A6 currently provides district steam for four (4) buildings: B49, B44, B43, & B23. The high-pressure steam (HPS) is regulated at 100 pounds per square inch, gauge (PSIG) at the plant and distributed through 2,400 feet of concrete steam trenches to four

(4) end-use buildings. At each of the end-use buildings, the steam is reduced to low- pressure steam (less than 15 PSIG) and used to heat heating-hot water, and in one case for Building 23A, to heat domestic hot water heaters.

REFERENCES:

1. “Decentralize Boiler Plant A6, Life Cycle Cost Analysis Final Report” by NAVFAC dated April 26th, 2015

2 ENVIRONMENTAL

2.1 EXISTING CONDITIONS

A limited asbestos inspection was performed on the mechanical rooms for Buildings 23A, 43, 44, and 49 and the steam trench running from Building A6 to Buildings 23A, 43, 44, and 49 focusing on areas scheduled for renovations.

No asbestos-containing materials were found in the mechanical rooms for Buildings 23A, 43, 44, and 49. The pipe insulations inside the steam trenches running from Building A6 to Buildings 23A, 43, 44, and 49 were found to be non-asbestos. The trench covers for the steam trenches are gasketed to the concrete trench liner with layers of asbestos-containing felt paper.

Asbestos-containing roofing cement is sporadically applied to the top of the trench covers.

Asbestos-containing pipe and tank insulation is known to be present in Building A6 from previous inspections. No additional asbestos inspection work was performed in Building A6.

A limited lead paint inspection was performed on the mechanical rooms for Buildings 23A, 43, 44, and 49 and the steam trench running from Building A6 to Buildings 23A, 43, 44, and 49 focusing on areas scheduled for renovations.

Lead-based paint was found as follows:

• No lead-based paint was found in the Building 23A mechanical room.

• No lead-based paint was found in the Building 43 mechanical room.

• The wood window frame in the Building 44 mechanical room was painted with lead-based paint.

• The floor paint in the Building 49 mechanical room area is lead-based.

• The yellow traffic marking paint on the steam trench covers is lead-based.

Lead-based paint on the roof deck, structural steel, and walls is known to be present in Building A6. No additional lead inspection work was performed in Building A6.

2.2 RECOMMENDATIONS

Trench covers with adhered asbestos-containing gasketing and/or roofing cement will be removed and disposed of as asbestos waste. The gasketing on the top of the concrete trench liners will be removed and disposed of as asbestos waste.

The wood window frame in the Building 44 mechanical room will remain in-place. The lead-based floor paint on the mechanical room floor in Building 49 will remain in-place.

The sporadically applied lead-based yellow traffic marking paint will be removed prior to trench cover removal.

The asbestos-containing pipe and tank insulation in Building A6 will be removed to make way for mechanical systems demo.

Lead-based paint on the roof deck, structural steel, and walls in Building A6 will be vacuumed free of loose paint, surfaces in the building will be wet wiped clean, and the roof deck, structural steel, and walls will be coated with a lead paint encapsulant to stabilize the paint in the building.

3 CIVIL

The purpose of this project is the decentralization of the existing steam infrastructure at the Newport Naval Health Clinic. The scope for the project includes removing the steam lines and abandoned water lines that originate at Boiler Plant A6 and service buildings 43, 44, 49, 23 and 23A. Where the steam lines pass under roadways the asphalt will be sawcut and removed to expose the trench covers. These areas will be repaved after reinstalling the trench covers. The steam for building 43 is direct buried from a manhole at the corner of Rossiter Rd. and Fitzsimmons Road. Building 23 is fed from building 23A by direct buried steam lines. Direct buried steam lines will be abandoned in place. The trench covers will be removed and disposed

of. The top 12” of the trench walls will be cut and removed. Every 25’ holes will be broken in the bottom of the trenches to allow for drainage. The trenches will be backfilled with crushed stone.

New concrete sidewalks and curbs will be installed where the trenches were acting as walkways. New handicap ramps will be installed at all road crossings. Where pavement is disturbed, new pavement will be installed. Disturbed grass areas will be loamed and seeded.

The section of trench along Fitzsimmons road with a railing is to have the wall along the roadway cut down to below the existing pavement. This will allow for the railing to be removed and the new sidewalk to be at 6” above the roadway. New gas services will be brought in from 3rd St. for buildings 23A, 43, 49, and 44.

4 ARCHITECTURAL AND STRUCTURAL

The existing steam piping entering buildings A6, B23A, B44, and B49 from the steam trenches is to be removed. The penetrations through the concrete foundations will be filled in with concrete and reinforcing as needed. The exterior face of the wall will receive waterproofing to prevent leaking where there are building basements.

In Buildings 23A and 49, there are trenches within the buildings. At B23A the trench is just to the east of the existing water heaters and is covered with a steel grate. The trench is open-ended and carries piping over to the pit. This is no longer needed so the trench will be filled and a slab will be installed flush with the main floor. The open end of the trench in the pit will be walled off with concrete. At B49 there is trench covered with removable concrete panels. The steam lines cross the building in the trench, over to the equipment on the east wall. This will no longer be needed so the trench covers will be removed, the trench filled in and a concrete slab will be poured over the fill, flush with the main floor. At building B43, the steam piping is direct buried so that the pipes coming through the foundation wall will be left in place and capped just inside the basement wall.

Existing concrete pads that are no longer needed or must be resized or relocated will be demolished and new reinforced concrete pads will be placed. Wall penetrations through foundation walls for boiler venting will be provided as required. Flat roof penetrations for the boilers and water heaters will be provided as required at building 23A. Supplemental steel frames will be provided at new roof penetrations.

5 MECHANICAL

5.1 MECHANICAL CODES & STANDARDS

The following codes and standards apply to this building:

UFC 1-200-01 DOD Building Code (General Building Requirements), 06-20-2016 UFC 1-200-02 High Performance and Sustainable Building Requirements, 12-01-2016 UFC 3-400-02 Design: Engineering Weather Data, 02-28-2003 UFC 3-401-01 Mechanical Engineering, with Change 1, 07-01-2013 UFC 3-410-01 Heating, Ventilating, and Air Conditioning Systems, with Change 3, 07-

01-2013 UFC 3-430-01FA Heating and Cooling Distribution Systems, 07-25-2003 2012 International Mechanical Code 2012 International Energy Code

5.2 EXISTING STEAM SYSTEMS AND CONDITIONS

5.2.1 BUILDING A6

Steam is generated from Boiler Plant A6 via (3) natural gas boilers and is distributed to (4) other facilities in the Naval Health Clinic via a system of trenches. These (3) boilers are described below.

(3) Natural Gas Boilers:

200 HP Cleaver Brooks Model No: CB600-200 Capacity: 8,369 MBH Max Working Pressure: 150 PSIG Current Operating Output Pressure: 100 PSIG

The current boiler arrangement has been in place since 1982. The plant in general contains piping dating back to the 1950’s when heating hot water and domestic hot water were generated at A6. Estimates from the Life Cycle Cost Analysis Report1 show the current load of the boilers at 6,536 MBTUH. This demand can be met by one of the boilers.

5.2.2 BUILDING 23A

Building 23A serves as the central utility plant (CUP) for the outpatient clinic, Building 23.

Steam is used to provide heating hot water and domestic hot water. Steam enters through a 6’ deep pit along the East wall where it is piped up to (2) heat exchangers for heating hot water and (2) domestic hot water heaters. The pit houses a duplex condensate receiver, a sump pump, and a pressure reducing station. If all of the steam equipment is removed from the pit, the pit will have no other purpose.

The (2) heating hot water heat exchangers are rated for a combined 4,250 MBTUH at a supply of 425 gpm with 160 °F entering and 180 °F leaving water. Heating water is distributed by (3) 10 HP pumps controlled by variable frequency drives.

5.2.3 BUILDING 43

Building 43 (Figure 23) serves as an administrative area for NHCNE. There are offices, consultation rooms, and a cafeteria among other functions. The plant equipment for Building 43 is located in the basement. Heating for this building is provided by (2) sources. The primary source is a low-pressure steam heat exchanger. The backup source of heat is an oil-fired boiler with (2) 250 -gallon fuel oil storage tanks. The backup boiler fuel system was reported to have issues with overfilling and the boiler is seldom used.

The existing heating hot water generating system for B43 includes (1) shell and tube heat exchanger and two (2) distribution pumps. The heat exchanger is rated to supply 140 GPM at 162.2°F entering and 180°F leaving. The heat exchanger has a capacity of 1,246 MBH. The heating hot water pumps have VFDs and are arranged in a variable primary configuration.

5.2.4 BUILDING 44

Building 44 (Figure 24) serves as an administrative and storage facility for NHCNE. There are administrative offices on the top three (3) floors with the basement primarily allocated for supply and equipment storage. Steam enters Building 44 in a small mechanical room under the loading dock.

The existing heating hot water generating system for 44 includes a single shell and tube heat exchanger and (2) distribution pumps. The heat exchanger is rated to supply 79 GPM @ 160 °F entering and 180 °F leaving. This equates to a peak capacity of 790 MBTUH. The heating hot water pumps have VFDs and are arranged in a variable primary configuration. The basis of design boiler selection is a high-efficiency condensing unit that is well suited for variable primary flow application.

5.2.5 BUILDING 49

Building 49 (Figure 25) serves as an administrative office, workshop, and garage for NHCNE Public Works. The building is single-story. Except for the admin portion, it is heated by radiant tubes and unit heaters. Steam enters Building 49 through a trench in the workshop. The trench continues to the back of the building where it crosses into the wash down bay.

In the wash down bay, a single shell and tube heat exchanger and a 3/4 HP distribution pump generate hot water. The heating hot water pump is constant volume. Through analysis provided in the Life Cycle Cost Analysis Report1, the building load is approximately 250

MBTUH.

5.3 PROPOSED MECHANICAL SYSTEMS

5.3.1 GENERAL DESIGN CONSIDERATIONS

Condensing type natural gas boilers were chosen for their efficiency. Heating loads were determined by the existing steam heat exchanger capacities at each facility. To meet the required heating demand, (3) boilers were specified for each location and sized to an N+1 redundancy configuration. This means that a number of N boilers are required to meet the full demand of the facility, with 1 boiler for redundancy.

5.3.1.1 GAS SYSTEMS

Gas is to be provided at building perimeter/exterior by utility. Trenches shall be provided for the Utility. The Utility will provide the piping and meter. The contractor shall be responsible for connecting to the utility meter.

5.3.1.2 CONTROLS

Controls for each facility shall tie into the existing BACnet through the existing Metasys controllers. Each boiler shall have its own factory controller to manage internal functions. The Metasys shall supply the factory controllers with a demand for heat call and a desired supply temperature. The Metasys controller shall in turn be configured to accept alarms and status parameters from the factory controllers. BACnet over MSTP shall be the communication protocol.

5.3.2 BUILDING A6

The complete steam boiler system shall be removed. All process equipment, piping, and controls are to be removed. The systems to remain shall be the main electrical distribution, lighting, receptacles, and domestic water.

The existing (2) generators will also be removed and turned over to the Navy. Each generator feeds a motor control center. With the motor control center’s no longer powering process equipment, the generators shall pose an unnecessary maintenance expense as well as a nuisance during power outages.

The domestic water is used for a wash sink, a water fountain, a hose reel, a safety shower, and a lavatory.

(3) gas unit heaters shall be provided to prevent freeze damage for the facility. A downsized meter is to be provided by the utility. New piping shall be run from the meter to each unit heater.

5.3.3 BUILDING 23A

The existing pit equipment, heat exchangers, pressure reducing station, associated steam equipment, and (2) domestic water heaters shall be removed. The existing primary pumps, expansion tank, and air separator will remain. The supply and return piping will be extended approximately 60’ to the new boiler configuration.

The boilers and domestic hot water heaters shall be installed in new locations to have the shortest possible cutover time.

(3) 2500 MBTUH condensing boilers shall be installed in existing open space. The existing pads in this location will be modified to support the new boilers. The (3) boilers shall be arranged in a variable primary/secondary flow configuration. They shall be vented vertically through the roof.

(3) replacement domestic water heaters shall be installed on the NW equipment pad where the MedVac unit sits. The MedVac unit will be moved to a temporary location until the steam system has been removed completely.

Power for the (3) boilers shall be supplied from Panel 1CHE1 (480V 3PH) located at the North end of the building. New branch wiring shall be run. The existing branch wiring for the (2) domestic water heaters shall be extended to the replacement water heaters.

The location of the new boilers and domestic hot water heaters shall enable minimal down time of both heating hot water and domestic hot water systems.

5.3.4 BUILDING 43

The existing auxiliary boiler, (2) fuel tanks, heat exchanger, associated steam piping, and condensate return shall be removed. The aux boiler exhaust vent shall be removed, but the shaft shall remain for venting of the replacement boilers.

The existing distribution pumps, expansion, tank, and air separator shall remain.

(3) natural gas fired condensing boilers shall be installed in the location of the existing fuel tanks & aux boiler. The (3) boilers will be arranged in a variable primary/secondary flow configuration.

Venting shall be routed through the existing shaft. The existing plenum shall be removed, and the louver sealed. The boiler intake and vents will terminate just below the sealed louver. The heating hot water send & return lines shall be extended and reworked to provide typical boiler air separator expansion tank pump flow scheme.

(1) 208V/120Y 100A electrical panel shall be installed to handle the boilers, circ pumps, & equipment as the existing panels in the basement are full. A feeder shall be installed from PNL LDP1 located in the 1st floor electrical closet, RM 1046.

5.3.5 BUILDING 44

The entire heat generation plant shall be replaced in building 44. The existing heat exchanger, air separator, expansion tank, condensate return pump, hot water distribution pumps, and associated steam piping shall be removed.

(3) natural gas condensing boilers shall be installed in the room under the loading dock. The (3) boilers will be arranged in a variable primary/secondary flow configuration. Venting for the boilers shall be through the south end wall of the mechanical room/loading dock.

A new 100A panel shall be provided in the mechanical room for powering the new equipment. A breaker in the existing MDB shall be provided to feed this 208Y/120V 100A 3PH panel. The MDB is located just outside the mechanical room.

5.3.6 BUILDING 49

(3) natural gas condensing boilers shall be installed in the garage space along with distribution pumps and expansion tank. The proposed location for the new heating system is located in the same place as the existing. This will cause a longer changeover time.

Electrical power for the installed equipment shall be supplied from panel in the North end.

6 APPENDIX

6.1 PROPOSED EQUIPMENT