Brdg Docs MenloPark-Mech Controls Drft V9 to GSA 022510.pdf

Mechanical and Controls Upgrade Projects Scope of Work & Concept Designs

USGS Geological Survey Campus

345 Middlefield Road Menlo Park, CA 94025

Prepared For:

Pacific, Gas & Electric

General Services Administration

Mark Levi

Buildings Services Branch 450 Golden Gate Ave. 4E 9PMFT

San Francisco, CA 94102

Prepared By:

100 Montgomery Suite 600

San Francisco, CA 94104‐4331

(415) 974‐0390

February 25, 2010

Copyright © 2010 GSA. All rights reserved.

For questions or comments pertaining to this report, contact Enovity Inc. Reproduction or distribution of the whole, or any part of the contents of, this document without permission of GSA is prohibited. Neither Enovity nor any of its employees makes any warranty, express or implied, or assumes any legal liability of responsibility for the accuracy, completeness, or usefulness of any data, information, method, product or process disclosed in this document, or represents that its use will not infringe any privately‐owned rights, including but not limited to, patents, trademarks or copyrights.

© 2010 Enovity, Inc. All Rights Reserved

Preface

Site Information

U.S. Geological Survey Campus, Menlo Park, CA 94025

Enovity Personnel

This work was performed by the following Enovity team members:

Name Company Role Phone Email

Jonathan Soper Enovity Inc. Principal 415‐974‐0390 jsoper@enovity.com

Eric Koeppel Enovity Inc. Technical Director 415‐974‐0390 ekoeppel@enovity.com

Jeff Guild Enovity Inc. Sr. Project Mgr. 415‐974‐0390 jguild@enovity.com

Tim Fackler Enovity Inc. Systems Eng 3 415‐974‐0390 tfackler@enovity.com

John Oldham Oldham Engineering Principal 510‐649‐9400 johno@oldhamengineering.com

Jim Dunham Oldham Engineering Principal Engineer 510‐649‐9400 jimd@oldhamengineering.com

Client Personnel

The following personnel were involved in the audit work:

Name Company Role Phone Email

Mark Levi GSA Buildings Management

Specialist, Region 9

(415) 522‐3374 mark.levi@gsa.gov

Bill McDonald Northern Mgmt Project Manager (650) 329‐4049 rmonsada@aleutfacilities.com

© 2009 Enovity, Inc. All Rights Reserved

Table of Contents

1.0 SUMMARY

2.0 BUILDING AND SYSTEM DESCRIPTIONS

OVERVIEW AND OPERATION

HVAC AIR-SIDE SYSTEMS

CHILLED AND HOT WATER SYSTEMS

CONTROL SYSTEM

3.0 ENERGY PROJECTS SCOPE OF WORK

BUILDING AUTOMATION SYSTEM & VAV CONVERSION UPGRADE PROJECTS

PROJECT 1A: CONVERT BUILDING 15 LABORATORY SPACES TO VARIABLE AIR VOLUME

PROJECT 1B: CONVERT NON-LAB AIR SUPPLY AND EXHAUST TO VARIABLE VOLUME

PROJECT 2: COMPLETELY REPLACE THE BUILDING 15 CONTROL SYSTEM

PROJECT 3: COMPLETELY REPLACE THE BUILDING 1 AND 2 CONTROL SYSTEM

PROJECT 4: COMPLETELY REPLACE THE BUILDING 3 CONTROL SYSTEM

PROJECT 5: COMPLETELY REPLACE THE BUILDING 3A CONTROL SYSTEM

PROJECT 6: INSTALL NETWORK COMMUNICATIONS TO CONNECT BUILDINGS TO A CENTRAL BAS

PROJECT 7: RE-COMMISSION VAV OPERATION FOR PACKAGE UNITS ON BUILDING 4

PROJECT 8: PRIMARY CHILLED WATER SYSTEM VARIABLE SPEED PUMPING, BUILDING 15

PROJECT 9: PRIMARY HOT WATER SYSTEM VARIABLE SPEED PUMPING, BUILDING 15

PROJECT 10: PRIMARY CHILLED WATER SYSTEM VARIABLE SPEED PUMPING, BUILDING 1 AND 2

PROJECT 11: SECONDARY HOT WATER SYSTEM VARIABLE SPEED PUMPING, BUILDING 1 AND 2

PROJECT 12: PRIMARY CHILLED WATER SYSTEM VARIABLE SPEED PUMPING, BUILDING 3

PROJECT 13: REPLACE THE AIR-COOLED TRANE CHILLER, BUILDING 1 AND 2

PROJECT 14: REPLACE THE AIR-COOLED MCQUAY CHILLER, BUILDING 3

PROJECT 15: INSTALL ECONOMIZER ON THE ROOFTOP AIR-HANDLERS, BUILDING 3A, 4 AND 11

PROJECT 16: INSTALL ENERGY METERS FOR ALL MAJOR HVAC EQUIPMENT, ALL BUILDINGS

1.0 SUMMARY

This document presents the scope of work and concept designs for the mechanical HVAC and controls upgrade projects at the USGS Geological Survey Campus located at 345 Middlefield Road, Menlo Park, CA. This document is presented in three (3) sections:

1. Summary

2. Building and System Descriptions

3. Energy Project Scope of Work

Project 1A: Convert Building 15 Laboratory Spaces to Variable Air Volume

Project 1B: Convert Building 15 Non-Lab Spaces to Variable Air Volume

Project 2: Completely Replace the Building 15 Control System o This project including re-programming the economizer for AHU-7

Project 3: Completely Replace the Building 1 and 2 Control System o This project includes implementing the Boiler OAT Lockout sequence

Project 4: Completely Replace the Building 3 Control System o This project includes implementing the Chiller OAT Lockout and CHW Pump Start- Stop sequences o This project also includes Reschedule the Air Handlers

Project 5: Completely Replace the Building 3A Control System o This project includes re-programming and re-commissioning the VAV operation for the package units

Project 6: Install Network Communications to Connect Buildings to a Central BAS Front End

Project 7: Re-commission VAV Operation for Package Units in Building 4

Project 8: Primary Chilled Water System Variable Speed Pumping, Building 15

Project 9: Primary Hot Water System Variable Speed Pumping, Building 15

Project 10: Primary Chilled Water System Variable Speed Pumping, Building 1 and 2

Project 11: Secondary Hot Water System Variable Speed Pumping, Building 1 and 2

Project 12: Primary Chilled Water System Variable Speed Pumping, Building 3

Project 13: Replace the Air-Cooled Trane Chiller, Building 1 and 2

Project 14: Replace the Air-Cooled McQuay Chiller, Building 3

Project 15: Install Air-side Economizer on the Rooftop AHUs, Building 3A, 4

Project 16: Install Energy Meters For All Major HVAC Equipment, All Buildings

2.0 BUILDING AND SYSTEM DESCRIPTIONS

This section provides a description of the existing building, HVAC and control systems at 345 Middlefield Road, Menlo Park CA. See also the GSA Mechanical Systems Operation Manuals for Buildings 1, 2, 3, 3A and 15.

OVERVIEW AND OPERATION

The USGS Menlo Park Campus is located at 345 Middlefield Road in Menlo Park, California. The campus includes 17 office and laboratory buildings and has an approximate floor area of 410,437 sq-ft. The projects are mostly in five buildings (Buildings 1, 2, 3, 3A and 15). The total square footage for Buildings 1, 2, 3, 3A and 15 is 347,150. Building 1 was completed in 1953; Building 2 in 1958; Building 3 in 1959;

Building 3A in 1959 and Building 15 in 1993. Buildings 1, 2, and 3 are 2 story office buildings. Building 3A is a one-story office building. Building 15 is a three-story laboratory building with one section of the building used as a dedicated library space.

The buildings are typically occupied Monday through Friday from 7:00 AM to 6:00 PM. HVAC equipment is typically operated from 4:00 AM to 10:00 PM except in Building 15. Due to fume hood requirements in Building 15, air handlers 1 through 6 operate continuously.

HVAC AIR-SIDE SYSTEMS

Building 1

Building 1 has four VAV packaged HVAC units located in the penthouse. The units have full air side economizer controls with variable frequency drives on the supply and return fans. All four units share and are located in a common outside air plenum. The units have chilled water cooling coils. The units supply 42 ceiling mounted VAV boxes with hot water reheat coils located throughout the building.

Building 2

Building 2 has six constant volume, 100% outside air, air handlers with no economizers. Each unit consists of a hot water and chilled water coil and are rated between 800 to 1200 cfm each. There are also 35 plenum-mounted fan coil units with heating and cooling coils, which provide terminal temperature control using re-circulated plenum air.

Building 3

Six (6) multizone air handlers serve building 3. Each air handler has supply and return fans, economizer dampers and hydronic hot and cold deck coils with 3-way control valves. The air handlers were retrofitted with variable volume distribution in a 1997 renovation project. The retrofit consisted of adding variable speed drives on the supply and return fans with the speed of the fan controlled to maintain a fixed discharge pressure setpoint. The static pressure sensor for the supply fan appears to be located immediately downstream of the fan before the ductwork splits into hot and cold decks. Units 5 and 6 operate on the same sequence of operation as the first four units, but are retrofitted with a packaged hot deck and cold deck fan units for the supply portion of the system. The hot and cold decks of these two units each contain the heating or cooling coil and variable frequency driven supply fan. A shared start / stop signal controls these supply fans. A seventh air handler is a typical VAV system, having ten (10) reheat type VAV terminals serving the zones.

There are pressure dependent VAV control dampers installed in each zone duct downstream of the zone mixing dampers. The dampers modulate to maintain a fixed duct pressure set point as sensed downstream of each damper. There are also variable volume (VAV) diffusers with self-contained actuators installed. The majority of the supply fan and return fan VFDs were operating at 100% indicating that the VAV conversion has been unsuccessful in reducing fan energy.

Building 3A

Packaged rooftop air handling units with 2-stage direct expansion (DX) cooling and staged gas-fired heating serve building 3A. Each unit has an economizer cycle with a dry bulb setpoint of 68°F. For Building 3A the air handlers deliver air through shutoff type VAV damper terminals. The available documentation was limited for Building 3A, but it appears that the air handlers operate as variable volume variable temperature (VVT) systems. It was not possible to determine from the BAS screens how effectively this system is operating.

Also, there are four split computer room air conditioning systems serving data processing rooms with raised floors in Building 3A. Thermostats and an internal control package independently control these units. These units are not on the building automation system.

Building 15

Building 15, also known as the McKelvey Laboratory is the main laboratory building, and is characterized by the large quantity of outside air necessary for making up exhaust air from the laboratory areas. Six large constant volume rooftop air handlers (AHU-1 through AHU-6) deliver 100% outside air to internal laboratories and perimeter offices. All of the supply fan motors (3 x 50 HP, 2 x 40 HP and 1 x 30 HP) are fitted with variable frequency drives, which have failed and have been placed in bypass, except for the one VFD (AHU 4). The variable frequency drives were set at individually fixed speeds (constant volume).

The supply air is delivered through commercial terminal boxes with hydronic reheat coils, each of which is configured to deliver a constant volume of air. Three exhaust manifolds, each of which uses 4 exhaust fans, exhaust all laboratory spaces and the associated perimeter offices. This exhaust is taken directly from room registers, as well as from approximately 112 constant volume fume hoods, canopies and cabinets (of which there are approximately 84 fume hoods). Independent exhaust fans exhaust a small number of other fume hoods (approximately nine), such as perchloric acid fume hoods and the radioactive fume hoods. There are a total of 28 exhaust fans with motors that vary between 0.5 and 20

HP.

A seventh VAV rooftop air handler (AHU-7) with a 60 HP supply fan and return fan serves the library and some other office and service spaces. This is a typical VAV system, having shutoff/reheat terminals, an economizer cycle and a return fan controlled by building static pressure. The motors for both the supply and return fans are fitted with variable frequency drives. This air handler is scheduled off at nights and on weekends.

All air handlers have hydronic heating coils with mostly 2-way control valves and cooling coils with mostly 3-way control valves.

The facility also has two air-cooled Liebert AC units and two air cooled McQuay direct expansion units that serve computer rooms.

Figure 2.3.1 Schematic of Building 1 Main Air Handlers in the Penthouse

Figure 2.3.2 Summary of Building 2 Air Handlers

Figure 2.3.3 Summary for a Typical Building 3 Multi Zone Air Handler

Figure 2.3.4 Typical Building 3A Multi Zone Air Handler

Figure 2.3.4 Typical Building 15 Laboratory Air Handlers

Table 2.3.1 through 2.3.3 summarize the main air handling units and exhaust fans that serve Buildings 1, 2, 3, 3A and 15.

Table 2.3.1 Buildings 1 and 2 Main Air Handlers

Building Number

Major HVAC Equipment

Heat Output

Cooling Output

Supply Fan Size

Supply Fan

Motor

Return Fan

Motor

Year Installed

Description

(Btu/hr) (Btu/hr) (cfm) (HP) (HP)

1 AH-1 195,000 15 5 2001

VFD controlled supply and return fans, cooling only AHU

1 AH-2 160,000 15 5 2001

VFD controlled supply and return fans, cooling only AHU

1 AH-3 160,000 15 5 2001

VFD controlled supply and return fans, cooling only AHU

1 AH-4 160,000 15 5 2001

VFD controlled supply and return fans, cooling only AHU

2 AHU 1-1 24,000 24,000

CFM

100% Outside air heating/cooling hydronic fan coil unit

2 AHU 1-2 48,000 36,000

1,200

CFM

100% Outside air heating/cooling hydronic fan coil unit

2 AHU 1-3 24,000 24,000

CFM

100% Outside air heating/cooling hydronic fan coil unit

2 AHU 2-1 24,000 24,000

CFM

100% Outside air heating/cooling hydronic fan coil unit

2 AHU 2-2 48,000 36,000

1,200

CFM

100% Outside air heating/cooling hydronic fan coil unit

2 AHU 2-3 24,000 24,000

CFM

100% Outside air heating/cooling hydronic fan coil unit

2 FCU A 18,000 9,000 300

100% Return air heating/cooling hydronic fan coil unit

2 FCU B 18,000 12,500 400

100% Return air heating/cooling hydronic fan coil unit

2 FCU C 30,000 16,500 600

100% Return air heating/cooling hydronic fan coil unit

2 FCU D 43,000 24,500 800

100% Return air heating/cooling hydronic fan coil unit

2 FCU E 50,000 28,500 1,000

100% Return air heating/cooling hydronic fan coil unit

2 FCU F 72,000 36,000 1,200

100% Return air heating/cooling hydronic fan coil unit

Air Handlers

Table 2.3.2 Buildings 3 and 3A Main Air Handlers

Building Number

Major

HVAC

Equipment Manufacturer Model Number

Size (Heating, Cooling, Flow)

Hot Deck Water Flow

Heat Output

Cold Deck Water Flow

Cooling Output

Supply Fan Size

Supply Fan Motor

Return Fan Size

Return Fan

Motor Efficiency

Year Installed

Description

(GPM) (Btu/hr) (GPM) (Btu/hr) (cfm) (HP) (cfm) (HP) (%)

3 AHU-1 21 210,000 126 630,000 21,000 15.0 16,000 5.0 N/A

Multi-Zone Hydronic

Air Handling Unit

3 AHU-2 15 150,000 79 395,000 13,000 10.0 10,000 3.0 N/A

Multi-Zone Hydronic

Air Handling Unit

3 AHU-3 16 160,000 82 410,000 14,000 15.0 11,000 3.0 N/A

Multi-Zone Hydronic

Air Handling Unit

3 AHU-4 13 130,000 67 335,000 11,000 7.5 8,000 1.5 N/A

Multi-Zone Hydronic

Air Handling Unit

3 AHU-5 800 CFM 21 210,000 76 380,000 13,000 10.0 10,000 3.0 N/A

Multi-Zone Hydronic

Air Handling Unit

3 AHU-6 1,200 CFM 24 240,000 86 430,000 14,000 10.0 11,000 3.0 N/A

Multi-Zone Hydronic

Air Handling Unit

3 AHU-7 McQUAY RDS802CLY 17 170,000 70 350,000 12,000 15.0 9,000 5.0 N/A Single-Package

Hydronic Rooftop Air Handling Unit

3 RTU-1 CARRIER 50TJQ004

3 TON

HEAT

PUMP

24,000 24,000 800 CFM 1.0 N/A N/A 10 SEER N/A

Single-Package

Standard Eff iciency Rooftop Heat Pump

3 RTU-2 CARRIER 50TJQ005

4 TON

HEAT

PUMP

34,400 35,600 1,200

CFM

1.0 N/A N/A 10 SEER N/A

Single-Package

Standard Eff iciency Rooftop Heat Pump

3A AC-1 Trane YCDO61C3HOBF 5 TON 135,000 60,000 2,000 N/A 1999

Gas Heating, Electric Cooling, constant volume roof top package unit w ith VVT boxes and bypass

3A AC-2 Trane YCDO121C3HOAA 10 TON 203,000 120,000 4,000 N/A 1999

Gas Heating, Electric Cooling, constant volume roof top package unit w ith VVT boxes and bypass

3A AC-3 Trane YCDO121C3HOAA 10 TON 203,000 120,000 4,000 N/A 1999

Gas Heating, Electric Cooling, constant volume roof top package unit w ith VVT boxes and bypass

Packaged AC Units

Table 2.3.3 Building 15 Main Air Handlers and Exhaust Fans

Major HVAC Equipment

Size (Heating, Cooling, Flow)

Heat Output Cooling Output

Supply Fan Size

Supply Fan Motor

Return Fan Size

Efficiency Description

(Btu/hr) (Btu/hr) (cfm) (HP) (cfm) (%)

AHU-1 50,000 CFM 1,731 MBH 1,890 MBH 50,000 40 N/A

VFD controlled supply fans, cooling and heating roof mounted, 100% OA, AHU

AHU-2 50,000 CFM 1,731 MBH 1,890 MBH 50,000 40 N/A

VFD controlled supply fans, cooling and heating roof mounted, 100% OA, AHU

AHU-3 50,000 CFM 1,731 MBH 1,890 MBH 50,000 50 N/A

VFD controlled supply fans, cooling and heating roof mounted, 100% OA, AHU

AHU-4 50,000 CFM 1,731 MBH 1,890 MBH 50,000 50 N/A

VFD controlled supply fans, cooling and heating roof mounted, 100% OA, AHU

AHU-5 50,000 CFM 1,731 MBH 1,890 MBH 50,000 30 N/A

VFD controlled supply fans, cooling and heating roof mounted, 100% OA, AHU

AHU-6 50,000 CFM 1,731 MBH 1,890 MBH 50,000 30 N/A

VFD controlled supply fans, cooling and heating roof mounted, 100% OA, AHU

AHU-7 50,000 CFM 1,731 MBH 1,890 MBH 50,000 50 36,000

VFD controlled supply fans, cooling and heating roof mounted, 30% OA, AHU, VAV

EF-1 15,000 CFM - - 15,000 7.5 N/A 89.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-2 15,000 CFM - - 15,000 7.5 N/A 91.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-3 15,000 CFM - - 15,000 7.5 N/A 91.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-4 15,000 CFM - - 15,000 7.5 N/A 91.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-5 15,000 CFM - - 15,000 15 N/A 92.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-6 15,000 CFM - - 15,000 15 N/A 92.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-7 15,000 CFM - - 15,000 15 N/A 92.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-8 15,000 CFM - - 15,000 15 N/A 92.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-9 15,000 CFM - - 15,000 7.5 N/A 91.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-10 15,000 CFM - - 15,000 7.5 N/A 91.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-11 15,000 CFM - - 15,000 7.5 N/A 91.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

EF-12 15,000 CFM - - 15,000 7.5 N/A 91.5%

VFD controlled exhaust fans, roof mounted, common plenum for each four fans

Exhaust Fans

CHILLED AND HOT WATER SYSTEMS

Building 1 and 2

The same central heating plant serves buildings 1 and 2. The central cooling plant consists of a reciprocating air-cooled chiller located outside on a pad just north of Building 2. The chiller utilizes its own internal control package. The building automation system enables the chiller. The boiler is a package boiler that is enabled or disabled via a Honeywell T-775 controller with an outside air temperature lockout of 65 deg F. Table 2.4.1 provides a summary of chillers, boilers and its associated pumps for Building 1 and 2.

Table 2.4.1 Buildings 1 and 2 Central Plant Summary

Building 3 & 3A

The chilled water system for Building 3 consists of a single air-cooled McQuay reciprocating chiller with two pumps (one operating, one standby). The chiller has an outside air lockout temperature of 65°F, which currently does not work properly. The chilled water supply temperature setpoint is 52°F.

The heating water system consists of a single flexible water-tube boiler with two pumps (one operating, one standby). There is no outside air temperature lockout for this unit. The hot water supply temperature setpoint is 170°F.

Building 3 has an equipment schedule of Monday through Friday from 4am to midnight, Saturday from 6am to 5 pm and Sunday from 9am to midnight. Table 2.4.2 provides a summary of the Building 3 heating and cooling equipment.

Building 3A has packaged roof top units with heating as describes above.

Building Number

Major HVAC Equipment

Heat Output

Cooling Output

Pump Motor

Efficiency Year

Installed Description

(Btu/hr) (Btu/hr) (HP) (%)

1 & 2 Chiller 3,000,000 1.12 kW/ton 2001 Air Cooled Srew Chiller

1&2 Boiler 2,268,000 81% 2001 Hot Water Boiler

1 & 2 CHWP-1 15 2001

Constant flow chilled water pump

1 & 2 CHWP-2 15 2001

Constant flow chilled water pump

1 & 2 HWP-1 5 2001 Constant flow hot water pump

1 & 2 HWP-2 5 2001 Constant flow hot water pump

1 & 2 BCP 1/2 2001 Boiler Circulator

Central Plant

Pumps

Table 2.4.2 Building 3 Central Plant Summary

Building 15

The chilled water system for Building 15 consists of two water-cooled 525-ton York centrifugal chillers.

Three chilled water pumps (75 HP each) are sized to match the flow of a single chiller. The middle pump is a standby pump that normally is off, but can be manually started to serve either chiller upon a failure of one of the other pumps. It is primary only constant flow chilled water distribution system. Each operating pump is piped directly to a chiller evaporator. The system serves the seven air-handler cooling coils through 3-way control valves. Control logic sequences the pump/chiller pairs based on fixed outside air temperature setpoints. The chillers turn on at 65°F increasing and turn off at 58°F decreasing outside air temperature. The chillers each have variable speed drives and adjusting inlet guide vanes and are lead-lag operated. Two condenser water pumps (50 HP each) circulate condenser water to a BAC cooling tower. The cooling tower has two cells, and each cell has two fans. The motor on each fan has two speeds (7.5 HP at low speed and 30 HP at high speed).

Two rooftop mounted flexible water-tube boilers (10 MBtu each) provide hydronic heat for air handlers and terminal units. Each boiler has dedicated pumps (15 HP each). A third standby pump is piped to allow it to be manually operated for flow through either boiler. A lead boiler operates continuously to serve reheat terminals, while the lag boiler is enabled on a fall in outside air temperature. These boilers are also the source of heat for domestic hot water. The hot water is heated in three semi-instantaneous type water heaters. Table 2.4.3 provides a summary of chillers, cooling tower, boilers and its associated pumps.

Building Number

Major

HVAC

Equipment Manufacturer Model Number

Size (Heating, Cooling, Flow)

Heat Output

Cooling Output

Pump Motor

Efficiency Year

Installed Description

(Btu/hr) (Btu/hr) (HP) (%)

3 Chiller McQUAY ALS235A 235 TON 1.18 kW/ton 1997 Air Cooled Screw

Chiller

3 Boiler Bryan HECL300-W-FDG

3,000 MBH

IN

MBH OUT

Gas fire f lexible w ater tube

3 CHWP-1 TACO FE4013-S53

605GPM at

140FT

40 1997

Constant f low chilled w ater pump

3 CHWP-2 TACO FE4013-S53

605GPM at

140FT

40 1997

Constant f low chilled w ater pump

3 HWP-1 TACO FE2007-S52

140GPM at

45FT

3 1997

Constant f low hot w ater pump

3 HWP-2 TACO FE2007-S52

140GPM at

45FT

3 1997

Constant f low hot w ater pump

Table 2.4.3 Building 15 Central Plant Summary

CONTROL SYSTEM

There are currently three (3) different control systems controlling Buildings 1, 2, 3, 3A and 15 at the Menlo Park Campus. The three (3) control systems are the CSI I2000, Barber-Colman Network 8000, and a Johnson Controls Metasys system. The CSI and Barber-Colman systems are obsolete and the Johnson system is using an older version of hardware that may soon become obsolete.

The CSI system currently controls Buildings 1 and 2. Building 1 is a two-story office building that has four

(4) air handling units and 42 VAV terminal boxes. Building 2 is a two-story office building with six (6) air handling units and 35 fan coil units. The two buildings share a common central plant consisting of one (1) boiler, one (1) chiller, two (2) heating water pumps and two (2) chilled water pumps. The CSI system runs at 19,200 bps on and EIA-232 network. The system consists of two (2) CSI I2000 panels and the I2000 front end running Windows 98.

The Barber-Colman Network 8000 system controls Building 15, which is a three-story laboratory building with an attached library. Air handling units 1 through 6 serve lab spaces (with approximately 84 fume

Major HVAC Equipment

Size (Heating, Cooling, Flow)

Heat Output Cooling Output

Pump Motor

Year Installed

Description

(Btu/hr) (Btu/hr) (HP)

Chiller 1 & 2 525 TON 5,280,000 1994 Water cooled centrifugal chiller, Open motor, Variable Speed Drive

Cooling Tower 1050 TON 30/10 1994 Dual cell, stainless steel, induced draft, two speed fan

Boiler 1 10,080 MBH 10,080,000 7.50 1994 Hot Water Boiler

Boiler 2 10,080 MBH 10,080,000 7.50 1994 Hot Water Boiler (check bearings)

CHWP-1 1260GPM @ 120FT 1994 Constant flow chilled water pump

CHWP-2 1260GPM @ 120FT 1994 Constant flow chilled water pump

CHWP-3 1260GPM @ 120FT 1994 Constant flow chilled water pump

HWP-1 360GPM @ 90FT 1994 Constant flow hot water pump

HWP-2 360GPM @ 90FT 1994 Constant flow hot water pump

HWP-3 360GPM @ 90FT 1994 Constant flow hot water pump

CTWP-1 1575GPM @ 90FT 1994 Constant flow condenser water pump

CTWP-2 1575GPM @ 90FT 1994 Constant flow condenser water pump

CTWP-3 1575GPM @ 90FT 1994 Constant flow condenser water pump hoods and 28 cabinets / canopy hoods) and office spaces throughout the building. Eight of the fume hoods are used for radioactive testing and one is designated for use with perchloric acid. There are a total of 28 exhaust fans. And a central plant with two chillers, two boilers, a cooling tower, and nine pumps. The Network 8000 system runs at 19,200 bps on and EIA-232 network. The system consists of four (4) Network 8000 Global Control Modules (GCM’s) and the Signal front end running Windows 98.

The Johnson system in Building 3 runs six (6) multi-zone air handlers with 31 zone monitoring units, one

(1) VAV air handler with ten (10) VAV terminal boxes, one (1) boiler and associated pumps and one (1) chiller and associated pumps in a two story office building. The Johnson Air Handling unit controllers are on an N2, RS-485 network running at 38,400 bps. Six (6) controllers speak to a Johnson FX-40 device that allows web-enable control.

The Johnson control system in Building 3A is similar in configuration to the system in Building 3. The building is a single story office building. The controls system is controlling five (5) rooftop, gas fired heating, DX cooling, air handling units. The air system is configured as a variable temperature and flow system with a bypass damper at each air-handling unit. The control system is networked back to the FX- 40 in Building 3 for communication back to the front end.

The three (3) controls systems are tied to a common Tridium Niagara AX front end via a 5.8MHz wireless network. Network communication is subject to interruption due to weather conditions and season. The seasonal issues are related to dense foliage on trees in line with the radio antennae, which causes interruption of network communications.

3.0 ENERGY PROJECTS SCOPE OF WORK

This section provides a scope of work for each project.

BUILDING AUTOMATION SYSTEM & VAV CONVERSION UPGRADE PROJECTS

The following general information applies to Projects 1 through 6:

Demolition of Existing Materials and Equipment: All existing hardware that is replaced including computers and controllers shall be packaged and returned to the Government.

Supervisory Controllers: All existing controllers shall be replaced with new BACnet controllers. New Control panels shall be provided to replace existing controllers. The JACE, global and air-handler controllers shall require an Uninterruptable Power Supply (UPS.) The new controllers shall be able to communicate to both the existing and new Tridium Niagara AX JACE controllers (without the need of additional Gateways.) All new BACnet controllers shall have, at a minimum, 20 percent expandability after installation of the system. All new existing JACEs will include, and all existing JACEs will be upgraded to include, as a minimum:

1. The most recent non-beta version of Tridium Niagara AX

2. BACnet Driver for the Tridium Niagara AX Supervisor

3. BACnet point bundles as necessary to encompass all points in this project and an additional 20% capacity for expansion

4. Upgrade the unit memory from 128Mb to an expanded memory of 256Mb including appropriate licensing.

5. Upgrade the license in the existing JACE to allow unlimited device connections

The JACE will communicate to the BAS Server using the Fox protocol.

No supervisory controller shall be utilized to a capacity that will affect the performance of the unit.

System Level Controllers: All existing system level controllers shall be replaced with the new BACnet Field Equipment Controllers (FECs). Existing control panels housing controllers shall be retrofitted to house new controller(s). All wiring (except where noted) and panel materials/devices shall be re-used.

Fire Life Safety System: There currently is no connection to the Fire Life Safety system.

Operator Workstation(s): Utilize the existing Tridium Niagara AX server (Server), including software and hardware. The Tridium Niagara AX License shall be upgraded to include the following:

The most recent non-beta version of Tridium Niagara AX

BACnet Driver for the Tridium Niagara AX Supervisor

BACnet point bundles as necessary to encompass all points in this project and an additional 20% capacity for expansion

BACnet Server driver

Install BAS software in (3) new operator workstations in Buildings 1&2, 3&3A and 20 and one new laptop.

GSA will provide computers and Contractor shall notify GSA of required computer specifications.

Graphics: The existing graphics shall be maintained for use by the building operator until new graphics are installed, commissioned and approved by the owner for use.

The graphics package shall be part of the submittal.

Communications and Networking: New Ethernet (TCP/IP) Cat 6 cable shall be installed to support and connect the new BACnet supervisory controllers and the new or existing Tridium Niagara AX JACE(s) Where there is no new supervisory BACnet controller, new MS/TP trunk shall be used to connect the FECs to the new or existing JACE(s). New MSTP trunk (to support BACnet over MSTP) shall be installed to connect the FECs to the new BACnet supervisory controllers. BAS networking between buildings to the existing Server will be covered in Project 6. Remove BAS network radio antennas from Buildings 1, 3 and 15 after Project 6 is complete and network connectivity between the JACEs and the Server is established and tested.

Sequence Programming: All programming shall be included in the design submittals or as detailed in the Specifications.

Commissioning: The contractor shall fully commission the new control system according to the commissioning process outlined in the specifications.

Point to Point Verification: All existing points must be maintained as part of the controls upgrade. The contractor shall conduct a complete point to point verification of the system after the new system has been installed, including all AO, AI, BO and BI points as well as virtual points. The contractor shall use the points list provided as the reference to complete this point to point verification. For all the AI points the contractor shall conduct sensor accuracy verification and include the following in tabular format: the device tested, BAS value, reading from calibrated device, difference between BAS reading and calibrated meter reading, % difference, required % error from specifications and pass/fail result. The contractor shall present a report that includes the complete point to point check and sensor accuracy verification, and identify sensors that need to be replaced. For sensors that fail, the Government may elect to have these sensors replaced by the contractor.

Points List: A complete points list shall be provided by the Contractor in the design submittal and at the end of the project completion in a format as defined in the specifications. All existing BAS points are required to be included in all applicable projects (i.e., carried over to the new BAS), as a minimum. The contractor shall determine the required new points to added. Any new points added, whether physical or virtual, shall be mapped to the Server and shall be readable and writable.

Training: The contractor shall provide training as outlined in the specifications.

Design and Documentation: The contractor shall provide design documentation, submittals and ‘as built’ project documentation as outlined in the specifications.

Sequence of Work: The contractor shall submit a Construction and Installation Plan addressing all building systems to ensure that all equipment remains fully operational during construction and equipment change out. The Plan shall include details on how the contractor will switch over to the upgraded control system without interruption to HVAC systems during working hours (6:00 AM to 6:00 PM). System shall maintain building temperature, pressure and ventilation requirements during occupied hours (Monday thru Friday 6:00 AM to 6:00 PM) while controls upgrade is being implemented.

PROJECT 1A: CONVERT BUILDING 15 LABORATORY SPACES TO VARIABLE AIR VOLUME

Scope of Work

The overall scope of work for Project 1A and 1B is to convert the air-side HVAC systems to variable air volume (VAV) control and install new VFDs on the existing air handlers and main exhaust fans. For Project 1A, a new Laboratory Control System (LACS) shall provide Variable Volume Control (VAV) control of the supply airflow and fume hood exhaust airflow in each laboratory room, and where necessary, VAV control of the general exhaust and other exhaust airflow (large canopies and cabinets). The scope of work for the conversion of the non-lab spaces to VAV control is covered in Project 1B.

General Requirements

1. The new LACS is not required to use the BACnet protocol, but is required to communicate to the new BAS Server using BACnet over IP (see Project 2 and 6). Any interface between the LACS and the BAS Server must be of the same manufacturer as the LACS. This interface must be able to handle communication from all lab controls and pass the required data to the BAS Server. The interface shall contain no programming or pass any variable to, or otherwise control any aspect of the LACS.

2. The new laboratory room controllers are included in this project. As part of the Project 2 scope, the contractor shall replace the existing controllers on AHUs 1 through 7 and Exhaust Fan 1 through 12 and the VAV terminal box controls for AHU-7 (replacement of the CAV box controls for AHUs 1 through 6 is included in the project 1A and 1B scope).

3. The design submittal shall include design drawings indicating the proposed modifications to the existing supply air and exhaust air duct work, including, but not limited to the locations of any new exhaust duct VAV devices (VAV boxes, modulating dampers or valves, etc.), fume hood exhaust valves, supply duct VAV devices, and any duct work modifications. Include final as-built drawings showing final installations, modifications and additions. Original hard-copy and scanned mechanical plans are available from the facility. The contractor is responsible for verifying the existing drawings and duct layout.

4. The contractor is not responsible for the existing conditions and integrity of the fume hoods. The contractor shall ensure that the existing fume hood constant volume airflows are maintained as the maximum VAV airflows (unless directed by GSA) and that the proper room volumetric offset, pressure control and minimum air changes are maintained. Design each new laboratory room VAV control system to comply with any safety requirements and all applicable codes.

5. Review the programmatic requirements of this building with GSA, including the minimum air changes and whether a space should be controlled as a laboratory space (with or without a fume hood) or as a non-lab space.

6. After completion of the engineering/design, conduct an initial installation (mock-up) in at least one lab containing a fume hood, to demonstrate the successful installation and control of the new laboratory room VAV controls prior to starting work in the other labs.

7. Phase the work as directed by the facility so ideally only one lab area is shut down at a time.

Provide construction barriers. Ensure that no contamination crosses construction barriers.

Coordinate all phasing with the building operation. The building will be in operation over the entire project duration.

a. For each phased space, determine from the USGS Campus Safety Officer and department head the safety and operational needs for that space, and for the surrounding spaces during construction.

b. Provide a written plan and schedule for phasing, including floor plans with each area to be phased, the order of phasing, the safety and operational requirements, the affects of construction on other areas, and mitigation measures to provide acceptable operation in adjoining areas. Submit a Phasing Plan and Schedule for approval.

c. The Phasing Plan and Schedule shall include a detailed schedule for demolition and installation of laboratory controls and any duct work installation. This schedule shall coordinate with the Principal Investigator (PI) of each lab via a Building Coordinator and the mechanical and electrical contractors. It is imperative for the success of this project that the schedule is adhered to. Each lab must be left in working order so the PI can resume work on their research.

8. Survey all existing fume hoods for size, airflow, type of use and safety requirements. Verify the list of the existing fume hoods, bio-safety cabinets, and canopies in Table 3.2 is accurate, and amend where inaccurate. The fume hoods, cabinets and canopies listed in Table 3.2 are also shown on the floor plans in Figures 3.1, 3.2 and 3.3.

9. Measure the existing airflow at all registers and hoods prior to commencing work on the building.

Measure the airflow, static pressure, RPM, and kW for all air-handling unit fans and exhaust fans.

10. Perform air balancing of the entire air-side systems (Project 1A and 1B together). Submit a TAB Plan for review and approval by the Owner. Coordinate the TAB work with the controls installation and commissioning. Submit the completed TAB report to the Owner for review and approval.

a. The interior laboratory spaces shall be negative to the exterior non-laboratory (office and common area) spaces and shall be balanced and controlled to maintain the proper volumetric offset and space pressure in each lab, as determined by the contractor’s mechanical engineer. The non-laboratory office and common spaces shall maintain a positive space static pressure to the exterior and to the labs.

b. The air balancing and new controls shall maintain the minimum air changes required for the building.

11. Replace or repair existing equipment that is no longer functional, in poor condition, and/or will not allow the rooms to be balanced and controlled properly.

12. Relocate existing ducts, pipes, conduits, or other equipment where necessary to provide space to install new equipment with manufacturer recommended clearances, and with clearances for maintenance.

13. Commission all equipment and controls per the commissioning specifications. Conduct a smoke containment test on 25 percent of the fume hoods (excluding the radioactive and perchloric fume hoods). Include in the commissioning, at least two x one (1) day training sessions of the new fume hood and canopy controls for the building lab occupants.

AHU & Exhaust Fan VFDs

14. Provide and install new variable frequency drives (VFDs) replacing the existing variable speed drives for exhaust fans EF-1 through EF-12 and air handlers AHU-1 through AHU-7 located on the roof as shown on Figure 3.5, Figure 3.6, and Figure 3.7.

a. The new VFDs shall include disconnects and a manual bypass; provide adequate support for mounting VFDs and disconnects in existing cabinets supports as shown in Figure 3.9.

b. Provide for each VFD: BACnet cards, by-pass switches and line reactors (see VFD specification).

c. As a minimum include the following AI points: VFD speed (Hz), Motor Amps, Fan kW, AO points: VFD speed signal, BO points: fan start/stop.

d. Install VFD controls connections and program controls. Commission VFDs. Balance airflows.

e. Coordinate shutdowns for installation of VFDs with Campus Safety Operator and other building personnel.

Laboratory VAV Conversion & Controls

15. Install new VAV laboratory control systems (LACS) in all laboratory rooms.

a. The interior core of the building contains laboratories, storage rooms, support rooms and restrooms. The outer exterior zones are offices and non-lab spaces. Air-handlers 1 through 6 provide conditioned air (100% outside air ventilation) to both the interior laboratory spaces and the exterior office areas (Air-handler 7 serves the library). All of the lab and non-lab exhaust air (fume hoods, canopies, cabinets, other equipment and general exhaust) are ducted together and exhausted by Exhaust Fans 1 through 12.

b. A sample, existing laboratory area duct layout is provided in Figure 3.4 See also the existing mechanical drawings. Sample photographs of the laboratory fume hoods are provided in Figure 3.10 and 3.11.

c. For this scope of work, the interior core spaces (including storage and support rooms) were assumed to be lab spaces versus the non-lab spaces in the exterior. There are approximately 157 individual lab rooms, of which approximately 58 labs have fume hoods (with eight of those having a radioactive or perchloric fume hood). There are approximately 84 fume hoods. Some labs have multiple fume hoods and there are many labs that do not have any fume hoods. Some labs contain ducted exhaust air for canopies, cabinets, snorkels and other exhaust (there are approximately 25 canopies and cabinets). Labs without fume hoods typically contain general exhaust and labs with fume hoods, canopies and miscellaneous exhaust typically do not have general exhaust.

i. Seven fume hoods (numbers 41 through 46 and 48 in Table 3.2) in lab rooms M3267 and M3263 have an existing, but older generation Phoenix Controls system (without sash position sensors). See the additional photographs provided at the end of this project scope of work. For these two lab rooms, there are four existing fume hood controllers mounted on the wall in the corridor outside lab M3263. There are existing air valves on each fume hood exhaust and each of the four supply terminal boxes serving these two labs. These existing air valves (total of 11) have pneumatic actuators. The scope of work does not change for these seven fume hoods and the four supply terminal boxes. The existing Phoenix controls and valves cannot not be re-used.

d. For air-handlers one through six, there are approximately 168 CAV supply terminal boxes with hot water reheat that serve the interior laboratory areas and approximately 171 CAV supply terminal boxes with hot water reheat that serve the exterior office (non-lab) areas.

The contractor shall review with the site, which spaces are considered laboratory spaces and which spaces are considered non-lab spaces.

e. There are approximately 8 labs with 8 radioactive and 1 perchloric fume hoods, each hood with a dedicated exhaust fan. These fume hoods shall remain as constant volume exhaust air with dedicated exhaust fans and the labs with these fume hoods shall remain as constant supply air. There is a constant volume exhaust fan (EF-22) that serves the chemical / explosive materials lab (M3079) that shall remain constant volume (1,520 design cfm; 0.75 hp). EF-22 is not connected to any fume hoods; it removes general exhaust from this single lab.

f. Install the laboratory controls per the manufacturer’s instructions. All of the laboratory room controllers, VAV controllers, CAV controllers and fume hood controllers must be from the same manufacturer. All sensors, exhaust dampers/valves or any other component must be either from the same manufacturer as the lab and fume hood controllers or recommended by the lab and fume hood controller manufacturer for use with their control system.

g. The new fume hood controllers (FHC) shall contain a resistance-type sash position sensor and operator display panel (ODP) for each sash arrangement on each fume hood.

The FHC shall maintain a constant face velocity across the sash, throughout the full range of the sash. The required face velocity shall be obtained from the Campus Safety Officer. If the Campus Safety Officer does not provide the required face velocity, 100 feet per minute shall be used. As the sash position is adjusted, the FHC shall adjust the fume hood exhaust airflow to maintain the constant face velocity across the sash.

h. Install the proper fume hood CAV to VAV conversion kit as determined by the manufacturer; note that the conversion kit is supplied by the manufacturer of the fume hood.

i. Ensure that the fume hood(s) are empty. If the fume hood(s) are not empty contact the Building Coordinator or Campus Safety Office as directed by the Owner to correct the situation.

j. Remove the existing controls.

k. For the laboratory rooms with radioactive fume hoods, the Nuclear Regulatory Commission (NRC) may require an Industrial Hygienist to perform the following as a minimum prior to work beginning in a radioactive lab (to be determined by the contractor):

i. Survey the lab for radioactive materials

ii. Survey the fume hoods for radioactivity and decontaminate as needed

iii. Survey any duct work that is included in the conversion of the lab

iv. If possible decontaminate any ductwork prior to its removal from the construction site

v. Perform any other procedures as required by law, code, OSHA or the NRC

l. The remaining scope of work is provided below and summarized in Table 3.1. See also Figures 3.12 through 3.15, which provide schematic diagrams for the scope of work outlined below and summarized in Table 3.1. Unit pricing is requested for the remaining scope of work, as the quantities of new controllers and control devices are estimated and may change upon completion of the design.

m. Electrical power panels for the labs are located in the corridors outside the labs. The new controls shall be fed from normal power, not emergency power.

Table 3.1 – VAV Conversion Scope of Work Summary

Area / Room Type Scope

Unit Pricing

Estimated Qty for

Unit Pricing Scope

Unit Pricing

Estimated Qty for

Unit Pricing Scope

Unit Pricing

Estimated Qty for

Unit Pricing

Labs with Fume Hoods or Large Process Canopies / Cabinets

New exhaust valve w/ fast acting actuator, airflow sensor and fume hood controller (one per hood) Y 75

New exhaust VAV device w/ actuator, airflow sensor and local min/max controller (one per large canopy/cabinet) Y 20

At a minimum, new fast acting actuator and lab room controller (LRC) for existing box

Y 70

Labs without Fume Hoods NA N NA

New exhaust VAV device w/ actuator, airflow sensor and misc. ductwork Y 100

At a minimum, new controller for the existing box (capable of space volumetric offset control) Y 90

Labs with a radioactive or a perchloric fume hood;

each hood with a dedicated exhaust fan (these 8 labs to remain constant volume)

At a minimum, new fume hood monitor (FHM) and sensor to replace existing for the radioactive fume hoods. New fume hood exhaust valve not required. Y 8

New exhaust damper/controls not required - contractor to determine if needed for constant volume room control (can be manually balanced). N NA

At a minimum, new CAV controller for the existing box (to replace existing controller; constant supply airflow for these labs) Y 8

Non-Lab Spaces (Office, Conf. Rooms, etc) - Project 1B (using BACnet controllers ) NA N NA

New exhaust VAV device w/ actuator, airflow sensor and misc. ductwork (one per each end of the brach duct between the interior lab space and exterior non-lab spaces - 12 per floor) Y 40

At a minimum, new VAV controller (BACnet) for the existing box (to replace existing controller) Y 171

Fume Hood Exhaust General & Other Exhaust Terminal Box Supply Air

n. Fume Hood Exhaust: Install a new VAV fume hood exhaust air valve (venturi type) with a fast-acting actuator and air flow sensor for each fume hood (one exhaust valve/actuator/sensor per each fume hood), wired to the new FHC. See Figure 3.12.

Contractor to determine the appropriate material type for the new fume hood exhaust valve; at a minimum it shall be 316L stainless steel. The FHC shall have a local emergency purge button. There are approximately 75 fume hoods (not including the one perchloric fume hood and the eight radioactive fume hoods).

i. A fume hood exhaust valve is not required for the 1 perchloric fume hood and the 8 radioactive fume hoods; they shall remain constant volume exhaust with a dedicated exhaust fan. At a minimum, a new fume hood monitor (FHM) and airflow sensor shall be installed on the existing 8 radioactive fume hoods, to replace the existing FHMs. See Figure 3.14. The perchloric fume hood is excluded from the project scope. The supply air for these labs shall also remain constant volume (these labs can be manually balanced for constant volume airflow). The FHM shall have an emergency button. The contractor shall determine if any additional controls are required for maintaining the constant supply and exhaust airflow and the minimum air changes in these labs with the radioactive fume hoods and the perchloric fume hood.

ii. The new fume hood exhaust valve shall use a new fast-acting actuator to control the fume hood exhaust airflow. The FHC and the fume hood exhaust valve actuator motor, in tandem, shall be able to cycle the actuator motor from full open to full close in less than one second.

o. General & Other Exhaust:

i. Labs with Fume Hoods or Large Canopies/Cabinets: The labs with fume hoods or large process canopies/cabinets appear to have been originally designed with the general room exhaust handled through the fume hoods and large canopies/cabinets and do not appear to contain any exhaust ducts/registers for general room exhaust.

The intent is to leave the small general and other miscellaneous exhaust ducts (less than 250 cfm) as constant volume without any new controls (manually balanced and spot measured exhaust airflow). The scope is to install a new VAV exhaust air device (valve or damper) with a standard actuator, air flow sensor and local on/off (min/max airflow) switch for each large process canopy or cabinet, greater than 250 cfm, wired to the local lab controller. See Figure 3.12.