SMRT Chiller EMS Study-Body.pdf

ARCHITECTURE ENGINEERING PLANNING INTERIORS ENERGY

PORTLAND, ME I ANDOVER, MA I ALBANY, NY I KEENE, NH I ALEXANDRIA, VA I www.smrtinc.com

Norfolk County Jail Dedham, Mass

Water Chiller Replacement and

HVAC Controls Upgrade Study

Massachusetts Project Number:

Contract No:

Prepared for Office of Programming

Division of Capital Asset Management By

SMRT, Inc.

June 27, 2014

SMRT Project No. 14067

Norfolk County Jail: Water Chiller Replacement & HVAC Controls Upgrade Study

SMRT Architecture Engineering Planning Interior Design Commissioning TOC - 1

Preface

This study was prepared for the Office of programming, Division of Capital Asset

Management, Executive Office of Administration and Finance, Commonwealth of

Massachusetts, as required by Mass. General Laws C.7 and C.29.

The study is intended to investigate agency needs, evaluate alternatives and define a preferred solution to the building project before final design begins and before a legislative decision is made to appropriate finds for implementation. After appropriation, if any, this study must be certified and thereafter no substantial changes can be made to the study solution during the implementation process.

The study culminates in a final schematic design which defines the preferred solution in terms of its content, time and cost, so that it provides a clear and detailed frame of reference for the design and implementation process. The schematic design has been included in the study for purposes of illustrating the preferred solution, demonstrating the practical operation of design criteria; codes and standards applicable to the project; and for developing accurate cost estimates. The form of the schematic design is not intended to constrain the final designer, but the functional program criteria, codes and standards must be followed in implementation.

The final designer should review the study and satisfy himself as to the accuracy of the contents before proceeding into design. However, it is expected that the study should save time and expense by avoiding unnecessary duplication of pre-design activities.

Norfolk County Jail: Water Chiller Replacement & HVAC Controls Upgrade Study

SMRT Architecture Engineering Planning Interior Design Commissioning TOC - 2

TABLE OF CONTENTS

Executive Summary Tab 1

Introduction Tab 2

Existing Conditions Tab 3

System Evaluation, Options, and Recommendations Tab 4

Codes and Standards Tab 5

Schematic Design Narratives Tab 6

Cost Estimate Tab 7

Appendix 1 – Photos Tab 8

Appendix 2 – Existing Drawings Tab 9

TAB 1

Norfolk County Jail Draft Final Report Water Chiller Replacement and HVAC Controls Upgrade Study 6-27-14

SMRT Architecture Engineering Planning Page 1 of 14

Part 1: Executive Summary

SMRT has been contracted by the facilities department of the Norfolk County Jail in Dedham, Massachusetts, to provide mechanical engineering services to evaluate the need for replacement of the chiller plant equipment, and the feasibility of replacing the existing stand-alone pneumatic equipment controls with a Direct Digital Control (DDC) based Building Automation System (BAS).

The existing physical plant was manufactured in 1991 and put into service in 1992, as part of the original construction of the facility. This puts the age of the equipment at approximately 22 years.

The median service life for pumps and chillers is 20-23 years (ASHRAE Applications Handbook), and as such, replacement of the systems and equipment should be planned now. New energy codes (ASHRAE

90.1-2007, and Massachusetts Stretch Code, IECC - 2009) have been put into place since the system was originally designed, which will require the existing constant flow system to be redesigned to a variable flow system. In addition, the air systems serving the detention areas do not meet current ventilation code (ASHRAE 62.1- 2007). As such, it is anticipated that additional ventilation will need to be provided by the air handling units when they are upgraded. This will add additional load to the already taxed chiller plant. Based on the higher ventilation rates, and what the industry is now seeing for cooling loads for this type of facility in this climate, we are recommending the existing 300 ton plant be designed with additional capacity.

The pneumatic HVAC control system also dates to the original building construction. This system has no remote or central monitoring, which makes it difficult to maintain the building climate, respond in real time to system issues, and diagnose operational issues. Electronic based DDC systems allow for this type of monitoring, trending and diagnosis of systems, plus allows for overall management of the system for occupancy scheduling and other energy management functions. Based on this, SMRT recommends that the pneumatic system be replaced with an electronic Building Management System

(BMS).

Converting control systems in an occupied building can be a complex process, particularly for a building that has access constraints due to security issues. The inherent access limits that will be in place on the job site will inhibit contractor productivity, driving the project cost up. Therefore the scope and phasing of the work needs to account for the age and condition of the systems being converted, and planned for in a systematic fashion. Knowing a majority of the major mechanical equipment is likely be replaced in the next 5-10 years, it is a good time to install the infrastructure for a DDC Building

Management System, while limiting the scope of work at the terminal control devices. The reasoning here is to maximize the ability of the facility to monitor the system operation from a central location, while limiting the initial investment in control components that may be replaced in several years.

The infrastructure should include the front end system architecture and programming, graphical user interface, HW, CHW plant control, and AHU level control. With this electronic Building Management

System in place, as equipment is replaced, or areas containing terminal control devices are renovated, the new components can be specified with electronic controls and tied into the building management system as part of the scope of work for those projects.

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An opinion of probable cost for upgrades of both systems was obtained from VJ Associates of Needham, Mass. Details of these estimates are enclosed in Section 6.

The estimated cost of the Chiller Plant replacement and upgrade of the existing pneumatic HVAC controls with an electronic Building Management System is approximately $1,550,000. Refer to the enclosed Cost Estimates for additional details.

TAB 2

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Part 2: Introduction

CHILLER PLANT

The facility’s chiller plant is served by two 150 ton water-cooled chillers. Both of the chillers, as well as the balance of chiller plant equipment, including but not limited to chilled water distribution pumps, cooling towers, and condenser water pumps, date from the original construction of the building in 1990. Based on a median service life of 20-25 years, the plant equipment is at the end of its life and need to be replaced within the next 1-2 years. As expected, the older systems and equipment continue to require ever increasing amounts of maintenance. Each of the chillers is designed to meet

50% of the cooling load on a peak design day. This means that if a chiller unexpectedly goes off-line because of an age-related or deferred maintenance issue, the ability of the plant to cool the building to an acceptable condition will be compromised.

Since the plant was designed in the early 1990’s, there have been changes in both the code ventilation rates (ASHRAE 62.1), energy efficiency requirements and climactic conditions. When the air handling units that provide ventilation to the building are replaced, they will be required to meet the current codes in place at that time. If additional ventilation needs to be brought into the building in order to meet current codes that will add to the cooling load of the building. Based on discussions with facility staff, the current plant operates at maximum condition during the cooling season, so the available capacity of the plant to meet potential load increases is unclear. This study will evaluate the load of the building based on the existing HVAC systems and current code ventilation rates and make a recommendation for the size of the replacement chillers and associated chiller plant equipment.

The chiller plant is also a candidate for energy efficiency improvement opportunities by employing current technologies and design and control strategies to reduce energy costs. The current configuration of the plant is constant flow, so both the chilled water and condenser water distribution pumps circulate water out to the equipment 24/7 during the cooling season, regardless of the load on the building. This does not meet current energy code. This study will evaluate the feasibility of upgrading the plant to a variable flow system to achieve electrical energy savings, and meet energy code requirements, in lieu of replacing the equipment in kind.

MECHANICAL SYSTEM CONTROLS

The existing mechanical systems are equipped with pneumatic controls, which date to the original construction of the building, 24 years ago. Pneumatic controls have a median service life of 20 years, and as such are past their expected lifespan, and should be considered for upgrade or replacement.

The system appears to be in fair condition, given their age.

In addition to age related issues, the system itself has major limitations in its ability to monitor and report the system status and performance to a central location. Currently, system information is only available locally at the associated control panel, which is installed adjacent to the equipment. As most of the equipment is located inside maximum security areas, satisfactory operation of the building’s mechanical systems is difficult and expensive. A modern distributed control system such as a Building

Automation system can monitor building temperature and ventilation status, system performance, device failure and malfunction alarms to a central and/or remote location for use by building engineering and/or maintenance staff and contractors.

SMRT Architecture Engineering Planning Page 4 of 14

This study will evaluate the feasibility of upgrading the existing pneumatic system to a modern, electronic Building Automation System, to allow for remote monitoring and operation of the building systems, and make recommendations as to how a new control system could be phased over time, considering the building occupancy, as well as the age of some of the mechanical equipment which are likely to be replaced within the next 5-10 years.

TAB 3

SMRT Architecture Engineering Planning Page 5 of 14

Part 3: Existing Conditions

CHILLER PLANT

The chiller plant was installed as part of the original construction of the facility in the early 1990’s. It shares space with the boiler plant in a common mechanical room located at the back of the building, with a large roll-up door for equipment access from a service yard. Access to the service yard is via a gate through the secure perimeter fence at the rear of the building.

The design capacity of the existing plant is 300 nominal tons, provided by two (2) 150 ton McQuay centrifugal chillers, manufactured in 1990. The plant configuration is primary loop, constant flow, with three (3) constant speed distribution pumps, each sized for 50% of the plant gpm, providing N+1 pumping capacity. Two Baltimore Air Coil cooling towers, each sized for 50% of the plant capacity, are located immediately above the chillers on the roof of the mechanical room. Three constant speed condenser water pumps provide N+1 pumping capacity.

There is currently no swing space in the mechanical room. Swing space is open space that would allow for the installation of new equipment while the existing equipment is still in place and operational.

Without available swing space, unit replacement will require removing the existing equipment from service for the duration of the construction work. This work will have to be scheduled to be completed outside of the cooling season, or temporary rental chillers will be required.

CONTROLS

The existing pneumatic system controls the following physical plant equipment:

Boilers plant

(2) HW Boilers

(3) Constant speed HW primary circulation pumps (N+1 standby)

(2) Constant speed HW secondary distribution pumps

(1) Glycol-to- HW HX

(2) Constant speed Glycol circulating pumps

(2) Constant speed Glycol distribution pumps

Chiller Plant

(2) Water-cooled chillers

(2) Cooling Towers

(3) Chilled water distribution pumps (N+1 standby)

(3) Condenser water pumps (N+1 standby)

Terminal Equipment

(4) Multi-zone Air Handling Units serving inmate areas

(4) VAV Rooftop AHU’s serving administration and staff areas

(4) Heating and Ventilating Units serving support areas (Kitchen, Laundry, and Gym)

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(1) Packaged Computer Room AC Unit

(4) Fan coil units

(32) Unit Heaters

(57) Variable air volume boxes

(9) Return fans

(45) Exhaust fans

Refer to Appendix 1 for the following Project Dwgs:

H-1 Symbols and Abbreviations

H-2 Jail – 1st Floor Plan

H-3 Jail – 2nd Floor Plan

H-4 Seg. Unit – 1st Floor Plan

H-5 Seg. Unit – 2nd Floor Plan

H-6 Central Unit – South Floor Plan

H-7 Central Unit – North Floor Plan

H-8 Central Unit – Mech Wing

H-9 HOC I – 1st Floor Plan

H-10 HOC I – 2nd Floor Plan

H-11HOC II – 1st Floor Plan

H-12 HOC II – 2nd Floor Plan

H-13 Not Included. (Pre-Release Building)

H-14 Flow Diagrams

H-15 Schedules

H-16 Schedules

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Part 4: System Evaluation, Options, and Recommendations

CHILLER SIZING, PLANT CONFIGURATION AND REDUNDANCY

The new plant must be sized to meet the current load, as well as any reasonably anticipated future loads of the building. Examples of future loads include planned expansion of the facility or program, or code required updates that are mandated when systems are replaced due to service life.

SMRT is not aware of any planned expansion to the facility, and therefore the chiller plant sizing assumes the current program, building footprint, envelope and occupancy will remain in its current state. SMRT has evaluated the existing systems, and has determined that the ventilation rates of the detention cells in the Jail, Segregation Unit, and House of Corrections is deficient in terms of the current ventilation code, ASHRAE 62.1-2007. Based on the age of the existing air handling equipment, we anticipate this equipment will be upgraded gradually over the next 5-10 years, and likely the system ventilation rates will be upgraded to meet the code at the time of the replacement. It is also likely, based on SMRT’s experience with jail HVAC design, that the increased ventilation rates may trigger a requirement to utilize exhaust air energy recovery to meet the requirements of the energy code. Energy recovery systems may reduce the cooling plant load; however, the mandates for increased ventilation rates will increase the plant load. While it is impossible to accurately predict the future load of the building based on future code requirements, and detailed design is outside the scope of this study, we can compare the current plant sizing with that of other correctional facilities of similar size that are designed to meet current ventilation and energy codes, and use this information to recommend the capacity of the plant to base the cost estimate on. Using this comparative analysis method, we recommend the total plant capacity be increased from 300 tons to at least 400 nominal tons.

Based on current energy code requirements, both the chilled water and condenser water systems will be required to be converted from a constant flow to a variable flow type system. In order to accomplish this, the system needs to be arranged either as a Primary Secondary Loop system, or a Variable Primary System.

A Primary Secondary system requires a set of constant speed pumps dedicated to a main (Primary) loop circulating chilled water through the chillers, and a set of variable speed pumps distributing chilled water to the terminal air handling equipment. In this configuration, the primary pumps ensure the chillers always have water flow.

A Variable Primary system requires a set of variable speed primary pumps that circulate chilled water through the chillers and distribute water to the terminal air handling units. In this configuration, a bypass valve is required to maintain minimum water flow through the chillers even at times of light load in the building.

SMRT studied both options for the new plant, and recommends it be configured as a Variable Primary system. The reasoning behind this is that the existing system is a constant speed primary system, so the new system will have similar space and electrical service needs, compared to a Primary Secondary, which would require an additional set of pumps. For this same reason, the Variable Primary system would be the lower cost option as well.

For critical applications such as jails, it is good engineering practice to avoid the use of a single large piece of equipment that could compromise a facility were it to fail, and utilize multiple pieces of equipment. For example, the current cooling plant utilizes two chillers, each sized at 50% of the building load, instead of a single chiller. We recommend the replacement equipment have a similar degree of redundancy.

SMRT Architecture Engineering Planning Page 8 of 14

If we were to match the existing configuration, a 400 ton plant with two identical chillers sized for 50% of the total load would require two 200 ton chillers. There are three types of chillers available in the 200 ton size range, listed in order of lowest cost/lowest efficiency to highest cost/ highest efficiency:

rotary screw, centrifugal, and magnetic-bearing centrifugal. Because the existing units are centrifugal, SMRT recommends the new machines be either a centrifugal, or a magnetic-bearing centrifugal machine, so that the performance of the new chillers matches or exceeds that of the existing machines.

There are some inherent difficulties when designing for a 200 ton centrifugal machine. 200 tons is at the lowest end of the capacity range of centrifugal machine, in fact, the smallest offering of some manufacturers is a 225 ton machine. Because of this, the turn down capability will be limited. Also, the cost per ton of the small centrifugal machine will be fairly high, and will drop as the size of this chiller is increased. For instance, a 300 ton centrifugal chiller can deliver 50% more cooling capacity than a 200 ton chiller, and yet it costs only 15% more.

SMRT evaluated various options for chiller sizes looking at both cost and redundancy, and recommends the following plant configuration: (1) 300 ton centrifugal or magnetic-bearing centrifugal machine, and (1) 150 ton water-cooled scroll chiller.

With this configuration, the 300 ton chiller will be the lead chiller and will operate to meet the base load of the building. It will be variable speed; it can turn down to 10% of load, and will have a high part-load efficiency. The 150 ton scroll chiller would initially be a standby chiller to provide 50% back-up capacity to the plant, in the event of the other chiller being down. It can also provide supplemental peak cooling should the building load increase in the future. The 150 ton chiller is a much lower cost chiller in terms of cost per ton, compared to a centrifugal chiller, but is more expensive to run, and is therefore a good candidate to act as an emergency chiller. The 300 ton centrifugal combined with a 150 ton scroll chiller will have a lower cost per ton compared to two 200 ton centrifugal chillers, making this a more economical choice overall.

Should this project proceed, the final designer should give serious consideration to using a magnetic bearing centrifugal chiller. Magnetic-bearing chillers cost an estimated 15-20% more than the oil-bearing centrifugal chillers, but have superior part load performance. It is anticipated that utility incentives may fund the added cost due to the potential energy savings. This needs to be evaluated in depth during the final design, based on the utility incentives available at the time.

CONTROLS

In order to achieve central system building management, remote monitoring and reporting, the existing pneumatic controls system needs to be upgraded to an electric/electronic based DDC system.

Currently, compressed air is used as a medium to control the HVAC systems, and is routed between the system sensors and control devices, such as valves and actuators. There is no capability for remote monitoring. In order to convert to DDC, new electronic sensors will be required, and each sensor will require wiring to actuators controlling VAV terminal boxes, dampers and valves, as well as communication wiring back to a central controller or system.

The major consideration to make when planning for the conversion of existing controls from pneumatic to DDC is whether to leave the pneumatic actuators in place, or replace them with new electronic actuators.

SMRT studied both options for the valve and damper actuators, and given the age and anticipated replacement of these components over the next several years, we recommend leaving the existing pneumatic actuators in place in the short term. This will require installing electronic to pneumatic

SMRT Architecture Engineering Planning Page 9 of 14 transducers on the devices to allow for communication with the new system, but is a much more cost effective option than replacing these devices now, and replacing them again in a few years when their systems are upgraded.

TAB 5

SMRT Architecture Engineering Planning Page 10 of 14

Part 5: Codes and Standards

International Building Code - 2009 with Massachusetts Amendments

International Energy Conservation Code - 2009 (Mass Stretch Code)

International Mechanical Code – 2009

248 CMR – MA Plumbing Regulations

International Fire Codes - 2009

ASHRAE 90.1-2007

ASHRAE 62.1- 2007

TAB 6

SMRT Architecture Engineering Planning Page 11 of 14

Part 6 Schematic Design Narratives

CHILLER PLANT

1. The system shall be configured as a variable primary only system, sized to deliver 450 tons of cooling capacity. One (1) 300 ton water cooled centrifugal chillers, and (1) 150 ton water-cooled scroll chiller shall be provided. Three (3) variable speed primary distribution pumps, each sized for 50% of the combined chiller flow, will distribute chilled water to the building.

2. This design provides full standby backup for the distribution pumps, and 50% redundancy for the chiller. This level of redundancy matches that of the existing plant, and is standard for this type of application.

3. Two (2) open type, evaporative cooling towers will be located on the roof above the chiller plant, and provide heat rejection for the chillers. Three (3) variable speed condenser water pumps, each sized for 50% of the system condenser water flow, will be provided. A side stream type condenser water filtration unit will be installed inside the building. The main chilled water headers will be 8”, matching that of the existing distribution. The new piping will tie-in to the existing inside the chiller room, and the existing emergency lines routed outside the building for an emergency chiller hook-up will be maintained.

a. Centrifugal Chiller: The centrifugal chiller shall have variable frequency drives and marine water boxes for the evaporator and condenser barrels. The chiller barrels shall be factory insulated with ¾” flexible elastomeric insulation. Basis of design: York YK or YMC2, 300 nominal tons.

b. Water-cooled Scroll Chiller: The scroll chiller shall be a high- efficiency self-contained unit, equipped with factory mounted microprocessor controls on a structural steel base. Basis of design York YCWL, 150 nominal tons.

c. Cooling Towers: Cooling towers shall be low-profile, open circuit, forced draft, counter-flow cooling towers. Cooling towers shall be located on the roof of the mechanical wing. Towers shall be equipped with variable frequency drives on the tower fans. Fan motors shall be premium efficiency totally enclosed fan cooled type.

Basis of Design: Baltimore Air Coil Model VTL, 450 ton capacity.

d. Pumps: Circulating pumps shall be separately coupled, vertical, inline centrifugal pumps. Pump shall be constructed with cast bronze impeller, stainless steel shaft, and oil lubricated, bronze, journal or thrust type bearings. Motors shall be premium efficiency open drip-proof type. Pumps shall be operated using variable frequency drives. Primary chilled water and condenser pumps shall be configured with two pumps operating in parallel and a third stand-by pump for redundancy. Basis of design:

Taco KS series

e. Solids Separator: The solids separator shall be a packaged simplex side stream system that includes housing with baffles and chambers, strainer, circulating pump, solids recovery vessel, piping and controls. Pump motor shall be premium efficiency totally enclosed fan cooled type. Basis of Design: Lakos TBX 400.

f. Water Treatment: Provide a complete water treatment package to control the chilled and condenser water systems. This includes but is not limited to biocides and corrosion

SMRT Architecture Engineering Planning Page 12 of 14 inhibitors. Condenser water chemical system shall include integral control panel to monitor and control the distribution of chemicals.

g. Controls: The chiller manufacturer shall provide all the necessary controls to operate the chiller plant including all chillers, pumps, cooling towers, sensors, and valves directly associated with the operation of the chiller plant.

h. Chilled Water Control Valves: As part of the chiller plant upgrade project, the existing three-way chilled water control valve on the eight air handling unit cooling coils shall be replaced with two-way valves, or the bypass port on the valve shall be disabled, to allow the system to operate as variable flow.

CONTROLS

1. Direct Digital Control System: A complete programmable microprocessor based electronic Lonworks/BACNet DDC building management system (BMS) shall be provided. Remote access shall be included over the Owner’s LAN.

2. The twelve (12) existing air handling units (ACU – 1 through 8, and HV-1 through 4) shall be converted from pneumatic to electronic control. This will allow for management and monitoring of the systems on a global level, including ventilation air, heating and cooling status, and discharge air temperature. Based on this, all new electronic sensors shall be provided to communicate with the new DDC controllers. The existing pneumatic valves and damper actuators shall remain in place, and be equipped with electronic to pneumatic transducers to allow them to be controlled by the new system. The new Sequences of Operation will duplicate the existing sequences.

3. All space and terminal sensors serving AHU-1, 2, 3 and 4, shall be replaced as part of the initial DDC conversion. These systems serve the detention cells, and for security reasons the zone sensors are located in the ductwork inside the mechanical room. As such, the sensors are easy to access and can be done at the same time as the air handling unit controls.

4. All space and terminal sensors serving HV-1, 2, 3 and 4, shall be replaced as part of the initial DDC conversion. These systems are single zone, serving kitchen, laundry and gym. As such the total quantity of sensors is low, and are easily accessed, and should be replaced at the same time as the work on the units is done.

5. The VAV terminals and associated space temperature sensors on air handling units ACU- 5, 6, 7, and 8 should not be converted until renovations of the space make it practical. These systems contain 57 VAV boxes, each of which requires a zone temperature sensors, damper and actuator, reheat coil and control valve. Conversion of these systems will be time consuming and require a great deal of above ceiling work, as well as cutting and patching of walls to allow for installation of the space sensors. For this reason, we recommend the terminal control conversion of these four systems be phased over time, as the spaces themselves are renovated, or when the VAV terminals are replaced due to age.

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Electrical

The existing chillers are fed from 225 amp breakers in main distribution switchboard located in the electrical room that is adjacent to the mechanical room. The new chillers will require that the existing breakers be changed to 300 amp breakers and new feeders run from the breaker to each new chiller. Existing feeders for chillers to be removed and a new feeder consisting of 3 #350 kcmil & #3, GND in a 3” conduit will be run to each chiller. The existing chiller pumps are fed from motor control center MCC-1 located at the east end of the mechanical. The existing pumps are constant volume pumps with starters and disconnects for the pumps located in the motor control center. The new variable volume pumps will have VFD’s and the starter and disconnect in the motor control center will need to be changed to a fused switch and a new feeder run to each of the six pumps. New feeders shall be 3#8 AWG & #10, GND run in a ¾” conduit from motor control center to VFD and then from VFD to pump. The existing cooling towers are also fed from MCC-1 and these feeders will need to be disconnected to allow for removal of cooling tower and reconnected to new cooling towers. The new DDC panels will require 120 volt circuit for each control panel. The circuits for these panels will be fed from existing emergency power panelboards located in electrical rooms at the north and south ends of the core and from a panelboard located in the main electrical room.

TAB 7

35 Highland Circle, Suite 200, Needham, Massachusetts 02494

Architect: SMRT

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate June 30, 2014

CHILLER & DDC UPGRADES

2 We assume the project would be complete within a six month timeframe including downtime.

General Conditions, General Reqmts.

Insurance & bond are included at 8.00%

4 Contractor OH&P included at 5.00%

5 Design Contingency is excluded - DCAMM will include this mark-up as part of the Total Project Cost (TPC)

6 Construction Contingency is excluded.

7 Escalation Contingency is excluded. We assume the project will be constructed within the next one year.

8 Phasing & Premium time 7.00%

June 30, 2014

NORFOLK COUNTY JAIL

Dedham, MA

This estimate is based on the Study Phase scope provided by SMRT in the drawings & specifications provided

ESTIMATE QUALIFICATIONS

Study Phase Estimate

VJ Associates Page 2 of 10

GFA Raw Rate/SF (excl all markups)

Individual Elements

Subtotal

Est. Cost % of ECC Notes

A Substructure $0.00 $0 0.00%

A10 Foundations $0

A1010 Standard Foundations 0

A1020 Special Foundations 0

A1030 Slab on Grade 0

A20 Basement Construction $0

A2010 Basement Excavation 0

A2020 Basement Walls 0

B Shell $0.00 $0 0.00%

B10 Superstructure $0

B1010 Floor Construction 0

B1020 Roof Construction 0

B20 Exterior Enclosure $0

B2010 Exterior Walls 0

B2020 Exterior Windows 0

B2030 Exterior Doors 0

B30 Roofing $0

B3010 Roof Coverings 0

B3020 Roof Openings 0

C Interiors $33.33 $10,000 0.71%

C10 Interior Construction $0

C1010 Partitions 0

C1020 Interior Doors 0

C1030 Fittings 0

C20 Stairs $0

C2010 Stair Construction 0

C2020 Stair Finishes 0

C30 Interior Finishes $10,000

C3010 Wall Finishes 10,000

C3020 Floor Finishes 0

C3030 Ceiling Finishes 0

D D10 Conveying $0.00 $0 $0 0.00%

D1010 Elevators & Lifts 0

D1020 Escalators & Moving Walks 0

D1090 Other Conveying Systems 0

D20 Plumbing $0.00 $0 $0 0.00%

D2010 Plumbing Fixtures 0

D2020 Domestic Water Distribution 0

D2030 Sanitary Waste 0

D2040 Rain Water Drainage 0

D2090 Other Plumbing Services 0

D30 HVAC $3,570.69 $1,071,206 $1,071,206 76.52%

D3010 Energy Supply 0

D3020 Heat Generating Systems 0

D3030 Cooling Generating Systems 477,308

D3040 Distribution Systems 86,153

D3050 Terminal & Package Units 0

D3060 Controls & Instrumentation 319,193

D3070 Systems Testing & Balancing 188,552

D3090 Other HVAC Systems & Equipment 0

D40 Fire Protection $0.00 $0 $0 0.00%

D4010 Sprinklers 0

D4020 Standpipes 0

D4030 Fire Protection Specialties 0

D4090 Other Fire Protection Systems 0

D50 Electrical $358.12 $107,436 $107,436 7.67%

D5010 Electrical Service & Distribution 93,136

D5020 Lighting & Branch Wiring 0

D5030 Communications & Security 0

D5090 Other Electrical Systems 14,300

June 30, 2014

Building Summary

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

Services

Total Program Area

VJ Associates page 3 of 10

GFA Raw Rate/SF (excl all markups)

Individual Elements

Subtotal

Est. Cost % of ECC Notes

June 30, 2014

Building Summary

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

Total Program Area

CHILLER & DDC UPGRADES

E $0.00 $0 0.00%

E10 Equipment $0

E1010 Commercial Equipment 0

E1020 Institutional Equipment 0

E1030 Vehicular Equipment 0

E1090 Other Equipment 0

E20 Furnishings $0

E2010 Fixed Furnishings 0

E2020 Movable Furnishings 0

F $152.61 $45,784 3.27%

F10 Special Construction $0

F1010 Special Structures 0

F1020 Integrated Construction 0

F1030 Vehicular Equipment 0

F1040 Special Facilities 0

F1050 Special Controls & Instrumentation 0

F20 Selective Building Demolition $45,784

F2010 Building Elements Demolition 45,784 F2020 Hazardous Components Abatement 0

Total $1,234,427

Z

$98,754 8.00%

Contractor OH&P $66,659 5.00%

$1,399,840

Contingencies

Design Contingency $0 0.00%

Phasing & Temporary Work $0 0.00%

Escalation Contingency $48,994 3.50%

Phasing & Premium time $101,418 7.00%

$1,550,253

Subtotal ECC Before Contingencies

Total ECC with contingencies

General Conditions, General Reqmts.

Insurance & bond

Special Construction & Demolition

Equipment & Furnishings

VJ Associates page 4 of 10

Code Description Quantity Unit Rate Assembly Cost

A SUBSTRUCTURE

A10 FOUNDATIONS

A1010 Standard Foundations $0.00 No Work

A1020 Special Foundations $0.00 No Work

A1030 Slab on Grade $0.00 No Work

A20 BASEMENT CONSTRUCTION

A2010 Basement Excavation $0.00

No Work

A2020 Basement Walls $0.00

No Work

B SHELL

B10 SUPERSTRUCTURE

B1010 Floor Construction $0.00

No Work

B1020 Roof Construction $0.00

No Work

B20 ENCLOSURE

B2010 Exterior Walls $0.00

No Work

B2020 Exterior Windows $0.00

No Work

B2030 Exterior Doors $0.00

No Work

B30 ROOFING

B3010 Roof Coverings $0.00

No Work

B3020 Roof Openings $0.00

No Work

Renovations to Main Building

June 30, 2014

CHILLER & DDC UPGRADES

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

VJ Associates page 5 of 10

Renovations to Main Building

June 30, 2014

CHILLER & DDC UPGRADES

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

C INTERIORS

C10 INTERIOR CONSTRUCTION

C1010 Partitions $0.00 No Work

C1020 Interior Doors $0.00

No Work

C1030 Fittings $0.00

No Work

C20 STAIRS

C2010 Stair Construction $0.00

No Work

C2020 Stair Finishes $0.00

No Work

C30 INTERIOR FINISHES

C3010 Wall Finishes $10,000.00 Patch & repair to existing 1 LS 10,000.00 10,000.00

C3020 Floor Finishes $0.00

In above

C3030 Ceiling Finishes $0.00

In above

D SERVICES

D10 CONVEYING

D1010 Elevators & Lifts $0.00 No Work

D1020 Escalators & Moving Walks $0.00

No Work

D1090 Other Conveying Systems $0.00

No Work

D20 PLUMBING

D2010 Plumbing Fixtures $0.00

No Work

D2020 Domestic Water Distribution $0.00

No Work

VJ Associates page 6 of 10

June 30, 2014

CHILLER & DDC UPGRADES

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

D2030 Sanitary Waste $0.00

No Work

D2040 Rain Water Drainage $0.00

No Work

D2090 Other Plumbing Systems $0.00

No Work

D30 HVAC

D3010 Energy Supply $0.00 No Work

D3020 Heat Generating Systems $0.00

No Work

D3030 Cooling Generating Systems $477,307.50

Centrifugal chiller 300 Ton 1 EA 191,231.20 191,231.20

Water cooled scroll chiller 150 Ton 1 EA 111,509.75 111,509.75

Cooling tower 225 Ton 2 EA 48,863.50 97,727.00

Chilled water pumps 3 EA 7,089.75 21,269.25

Condenser pumps 3 EA 3,601.80 10,805.40

Solid separator 1 EA 20,810.40 20,810.40

VFD for chilled & condenser water pumps (supply only) 6 EA 2,875.00 17,250.00

Water treatment system 1 LS 6,704.50 6,704.50

D3040 Distribution Systems $86,153.40

Chilled water piping 1 LS 38,295.00 38,295.00

Insulation 1 LS 9,568.00 9,568.00

Piping connections 1 LS 10,718.00 10,718.00

Two way valve 8 EA 1,244.30 9,954.40

Strainer, valves 1 LS 17,618.00 17,618.00

D3050 Terminal & Package Units $0.00

No Work

D3060 Controls & Instrumentation $319,193.00

DD Control Points

Chiller 32 EA 804.00 25,728.00

Cooling tower 24 EA 804.00 19,296.00

Pumps 18 EA 804.00 14,472.00

AHU 160 EA 804.00 128,640.00

H&V unit 80 EA 804.00 64,320.00

VAV units Not included

Solid separator 3 EA 804.00 2,412.00

VJ Associates page 7 of 10

June 30, 2014

CHILLER & DDC UPGRADES

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

Programming, software & training 1 LS 24,104.00 24,104.00

Head end equipment, computer & terminals 1 LS 40,221.00 40,221.00

D3070 Systems Testing & Balancing $188,552.28

Submittals & shop drawings 1 LS 10,097.00 10,097.00

Mobilization 1 LS 5,047.35 5,047.35

Chemical treatment 1 LS 4,172.20 4,172.20

Cleaning, identification & tagging 1 LS 5,662.60 5,662.60

Vibration controls 1 LS 14,938.50 14,938.50

Seismic restraints 1 LS 8,038.50 8,038.50

Rigging 190 HRS 76.48 14,530.25

Balancing 80 HRS 76.48 6,118.00

Testing & Commissioning 160 HRS 76.48 12,236.00

Cut, patch & paint 1 LS 7,120.80 7,120.80

Allow for unforeseen works 1 LS 0.00 100,591.08

D3090 Other HVAC Systems & Equipment $0.00

No Work

D40 FIRE PROTECTION

D4010 Sprinklers $0.00

No Work

D4020 Standpipes $0.00

No Work

D4030 Fire Protection Specialties $0.00

No Work

D4090 Other Fire Protection Systems $0.00

No Work

D50 ELECTRICAL

D5010 Electrical Service & Distribution $93,136.39 New Chiller Work

Shutdown Existing Main Distribution Switchboard & Open

Switchboard 1 EA 1,706.25 1,706.25

Install 300A Breakers for New Chiller 2 EA 4,127.50 8,255.00

3 #350MCM & #3 Gnd in 3" Conduit - Allow (100LF each) 200 LF 125.21 25,041.25

Startup & Testing 1 EA 2,559.38 2,559.38

New Chiller Pump Work

Shutdown Existing MCC-1 in Mechanical Room 1 EA 975.00 975.00 Remove Existing Starters & Disconnects for the Pumps Located in

Motor Control Center 5 EA 121.88 609.38

New Fused Switch in MCC-1 6 EA 1,592.50 9,555.00

VJ Associates page 8 of 10

June 30, 2014

CHILLER & DDC UPGRADES

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

Remove existing feeders 900 LF 4.02 3,619.69

3 #8 & #10 Gnd in 3/4" Conduit (MCC to VFD - Allow 50 LF each) 300 LF 23.29 6,987.83 3 #8 & #10 Gnd in 3/4" Conduit (VFD to Pumps - Allow 150 LF each) 900 LF 23.29 20,963.48

Startup & Testing 6 EA 487.50 2,925.00

New Cooling Towers Work

Disconnect Feeders Existing Cooling Towers 1 EA 243.75 243.75 Furnish 120V of Power for each Cooling Tower DDC Panel (Allow

200LF each) 400 LF 19.36 7,745.40

Reconnect Feeders for New Cooling Towers 2 EA 487.50 975.00

Startup & Testing 2 EA 487.50 975.00

D5020 Lighting & Branch Wiring $0.00

No Work

D5030 Communications & Security $0.00

No Work

D5090 Other Electrical Systems $14,300.00

MISC

Drawings/Engineering/Submittals 40 HRS 121.88 4,875.00

Permits 1 LS 1,950.00 1,950.00

Penetration, Patching & Fire stoppings 16 EA 467.19 7,475.00

E EQUIPMENT & FURNISHINGS

E10 EQUIPMENT

E1010 Commercial Equipment $0.00

No Work

E1020 Institutional Equipment $0.00

No Work

E1030 Vehicular Equipment $0.00

No Work

E1090 Other Equipment $0.00

No Work

E20 FURNISHINGS

E2010 Fixed Furnishings $0.00

No Work

E2020 Movable Furnishings $0.00

VJ Associates page 9 of 10

June 30, 2014

CHILLER & DDC UPGRADES

NORFOLK COUNTY JAIL

Dedham, MA

Study Phase Estimate

F SPECIAL CONSTRUCTION & DEMOLITION

F10 SPECIAL CONSTRUCTION

F1010 Special Structures $0.00

No Work

F1020 Integrated Construction $0.00

No Work

F1030 Vehicular Equipment $0.00

No Work

F1040 Special Facilities $0.00

No Work

F1050 Special Controls & Instrumentation $0.00

No Work

F20 SELECTIVE BUILDING DEMOLITION

F2010 Building Elements Demolition $45,784.25

HVAC

Remove the chiller 2 EA 9,941.75 19,883.50

Remove chiller pumps 2 EA 458.85 917.70

Remove cooling tower 2 EA 2,753.10 5,506.20

Remove condenser water pumps 3 EA 382.57 1,147.70

Remove chilled water piping 1 LS 4,129.65 4,129.65

Cap the pipe 1 LS 3,139.50 3,139.50

Remove pneumatic piping 1 LS 3,059.00 3,059.00

Demo 3 way valves 8 EA 191.19 1,529.50

Miscellaneous demo 1 LS 3,059.00 3,059.00

Electrical Remove Existing 225A Chiller Feeders - (Allow 100 LF each) 200 LF 12.19 2,437.50

Remove 225A Breakers in Existing Main Distribution Switchboard 2 EA 487.50 975.00

F2020 Hazard Components Abatement $0.00

VJ Associates page 10 of 10

APPENDIX 1 –

PHOTOS

Existing Chiller #1

Existing Chiller #2 & CHW Pumps keverett Callout CHW Pumps

Existing Condenser Water Pumps

Chiller Nameplate Data

Emergency Connections for temporary Chilled Water

Access to Mechanical Room

Callout Roll-Up Door to Mechanical Room keverett

CHWS/R Connections for Temporary Chiller

Chiller #1, and Access to Mechanical Yard

Existing Cooling Towers

Roll-Up Door to Mechanical Yard

Existing Towers, Rear Side Piping

Existing Pneumatic Control Panel

Typical Multi-Zone AHU

Typical Detention Area Mechanical Room

Typical Control Panel in Administration Area

Typical Space Temperature Sensor

Zone Temperature Sensor in Administration Area

Typical Roof Mounted Equipment

Typical Roof Mounted Equipment

Typical VAV Air Handling Unit keverett Callout Rooftop AHU's

Arrow

APPENDIX 2 –

EXISTING

DRAWINGS