SOW APPENDIX 12 - Bldg 2324 HVAC Survey Report.pdf

Heating, Ventilation, and Air Conditioning Equipment Survey

Building 2324 Patch Barracks

Stuttgart, Germany 1

Heating, Ventilation, & Air Conditioning Equipment Survey

Building 2324

Patch Barracks

Stuttgart, Germany

5 March 2020 DRAFT Site Visit: 1 November 2019

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Stuttgart, Germany 2

Abstract: A survey of the existing Heating, Ventilation, and Air Conditioning (HVAC) equipment was performed on 1 November 2019. Multiple aspects of the existing facility were evaluated to identify equipment and systems that are in need of repair. Results of the survey and subsequent engineering analysis and assessment will be used to inform future spending on the existing infrastructure.

Prepared by:

Engineering Branch Design Section US Army Corps of Engineers, Europe District Konrad-Adenaeur-Ring 39 65187 Wiesbaden, Germany

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Heating, Ventilation, and Air Conditioning Equipment Survey

Building 2324

Patch Barracks

Stuttgart, Germany

Table of Contents

Executive Summary

Purpose

Critical Findings

Recommendations

Further Study

Introduction

Background

Process

Objective and Scope

Project Contacts

EUCOM-DIA

USACE Europe District Survey Team

Background Data

References

Observations

Building 2324 Observations

General Facility Description

Administrative Area

Server Room 127

Server Rooms 106 & 108

Miscellaneous Remaining Equipment

Conclusions and Recommendations

Conclusions

Appendices

Table 1 – Summary of Equipment Observations and Recommendations

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Photographs

Photograph 1 – Three Carrier Air Cooled Chillers

Photograph 2 – Alternate View for Carrier Chillers

Photograph 3 – Carrier Chiller Unresolved Maintenance Items

Photograph 4 – Cabero Free Cooler/Economizer

Photograph 5 – Exhausto DOAS and Cabero Economizer

Photograph 6 – Administrative Area VRV Condensers

Photograph 7 – Administrative Area VRV Condensers and Piping

Photograph 8 – Administrative Area VRV Condensers Maintenance Item

Photograph 9 – Administrative Area AHU

Figures

Figure 1 – List of Mechanical Equipment by Grouping Number

Illustrations

Illustration 1 – Existing Mechanical Equipment Locations

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Executive Summary

Purpose

Personnel of the U.S. Army Corps of Engineers (USACE) Europe District, Wiesbaden, Germany conducted a field survey of EUCOM-DIA Building 2324 on Patch Barracks, Stuttgart, Germany on 1 November 2019. The site visit included a walk-through of the entire facility with information provided regarding the intent of the spaces and current issues with operations from the Facility Program Manager, Vincent Del Signore.

The purpose of this report is to provide an engineering assessment of the existing HVAC equipment to recommend necessary repairs to the existing facilities in order to improve the operational efficiency and reliability.

Only critical findings and corresponding recommended solutions are presented in this Executive Summary. A complete explanation of survey observations and subsequent recommendations are presented in the full text of the report.

Critical Findings

Several critical deficiencies were identified during the site visit, the following are the most notable:

a. The facility does not have a centralized building management system (BMS) to monitor and control the various systems and individual components. Not having this system makes it extremely difficult to know how the system is operating which prevents the operators from running the equipment optimally and avoiding costly downtime and unnecessary repairs.

b. The facility has over 27 pieces of exterior mechanical equipment serving 8 separate systems with more than 1,700 kW of cooling capacity. Despite the abundance of capacity and equipment, there are still spaces that cannot maintain the required space temperatures. The quantity of equipment and the various creates a significant workload from a maintenance standpoint which is evidenced by the various states of disrepair and glaring maintenance issues.

c. Room 127: The largest server room in the facility has several issues. There is inadequate air movement throughout the room which creates uneven temperatures in the space, this combined with sub-optimal computer room air handler (CRAH) unit operation and insufficient cooling capacity creates a space temperature than is not optimal for the equipment.

d. Conference Room 0107: This conference room has a ceiling cassette that is undersized and has ceiling damage from condensation.

Recommendations

The following repairs/renovations to the facility are recommended as solutions to the critical deficiencies noted above:

a. Provide a new facility wide BMS with two workstations, one for the facilities manager in Room 103 and one in Room 109 for the data center manager. The system shall be capable of connecting to all of the HVAC systems throughout the facility. Coordinate all new mechanical equipment to ensure compatibility with BMS.

b. All existing mechanical equipment associated with Room 127 shall be disconnected, removed, and disposed. This includes the eight interior CRAH units and their associated

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Remove the existing raised floor tiles and replace in accordance with necessary modifications to the server room to maintain separation between the cool supply air to be delivered to the racks and the warm return air to be delivered to the CRAH inlet.

c. Remove three Carrier chillers on the roof and associated equipment. All in-row coolers in Rooms 106 and 108 should remain in-place and be utilized in the new system if possible.

d. Remove all existing HVAC equipment in the administrative area (non-server rooms).

e. Provide new HVAC system(s) for the facility that are compatible with the new BMS.

Include energy recovery and economizer systems to the fullest extent possible. Design system(s) that utilize similar technology to streamline maintenance and minimize equipment types. Areas needing replacement system(s) include:

i. Server Room 127: New interior computer room units with underfloor air distribution. Equipment will satisfy facility N+1 requirements.

ii. Server Rooms 106 and 108: New exterior heat rejection equipment to be provided. Optimal solution would be to combine heat rejection with Room 127 equipment to increase viability of waste heat recovery. Equipment will satisfy facility N+1 requirements.

iii. Administrative area: All offices, training, and conference rooms to be provided with new HVAC equipment.

Further Study

An engineering study should be conducted to determine the current engineering constraints prior to the execution of any major repairs. The engineering study should include the following at a minimum:

a. Perform an inventory of existing equipment, operational capacities, and sequence of operations;

b. Conduct a detailed heating and cooling load calculation for the facility;

c. Perform an in-depth assessment of compliance of the existing facilities with all applicable standards and guidance;

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Introduction

Background

The EUCOM-DIA Building 2324 is located in Stuttgart, Germany. The existing facility consists of two distinct portions. The original building was constructed in the mid-twentieth century as motor pool and maintenance facility. An addition to the facility and renovation of the original building was completed in 2005.

Functionally, the building consists of three separate server rooms, conference rooms, offices, a kitchenette, and two separate restroom areas. Finished spaces include lighting, radiator heating, automatic fire suppression sprinklers, and all wood framing has been covered with gypsum wallboard.

Building 2324 is a Sensitive Compartmented Information Facility (SCIF).

Process

EUCOM-DIA hired the US Army Corps of Engineers (USACE) to conduct an engineering analysis of the existing Building 2324 mechanical equipment.

A site visit was conducted on 1 November 2019. The Project Delivery Team (PDT) was made up of USACE engineers, Objective and Scope

The primary objective of this investigation was to observe the existing HVAC equipment and to recommend necessary repairs/renovations to the existing facilities in order to improve the reliability and efficiency of the operations. These objectives were accomplished by:

a. Performing a site visit to observe existing conditions.

b. Performing independent engineering analysis on existing conditions.

c. Producing a detailed report detailing the observations and recommendations resultant from the site observations and subsequent independent engineering analysis.

The results of this study can be used to:

a. Socialize proposed improvements within the Garrison and facilities management.

b. Inform future investigations or studies.

Project Contacts

EUCOM-DIA

a. Vincent Del Signore Facilities Program Manager - Europe Vincent.DelSignore@dodiis.mil, Phone: +49-711-680-5672

USACE Europe District Survey Team

b. Andrew Duffe Project Manager andrew.e.duffe@usace.army.mil, Phone: +49-611-9744-2474 mailto:Vincent.DelSignore@dodiis.mil mailto:andrew.e.duffe@usace.army.mil

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c. Marcus Ballnath, AKH Architect marcus.c.ballnath.ln@usace.army.mil, Phone: +49-611-9744-2310

d. Desiree Boger, PE Electrical Engineer desiree.n.boger@usace.army.mil, Phone: +49-611-9744-2673

e. Daniel Hilgendorf, PE Mechanical Engineer daniel.r.hilgendorf@usace.army.mil, Phone: +49-611-9744-2042

f. Reemt Pauw Cost Engineer reemt.j.pauw.ln@usace.army.mil

Background Data

References

The following references have been considered during the engineering analysis and subsequent development of recommendations:

a. IMCOM-E Guidelines for Offices

b. UFC 1-200-01 DoD Building Code

c. UFC 1-200-02 High Performance Sustainable Buildings

d. UFC 3-110-03 Roofing

e. UFC 3-110-04 Roofing Maintenance and Repair

f. Baden-Wuerttemberg State Construction Laws

g. UFC 3-501-01 Electrical Engineering

h. UFC 3-520-01 Interior Electrical Systems

i. NFPA 70 National Electrical Code

j. NFPA 101 Life Safety Code

k. DIN VDE 0250 Cables, wires and flexible Cords for Power Installations

l. DIN VDE 0298 Application of Cables and Insulated Cords for Power Installation

m. DIN VDE 0660 Low Voltage Switchgear and Control gear

n. UFC 3-400-02 Design: Engineering Weather Data

o. UFC 3-401-01 Mechanical Engineering

p. UFC 3-410-01 HVAC Heating, Ventilating, and Air Conditioning Systems, with Change 4

q. UFC 3-410-02 DDC for HVAC and other building Control Systems

r. UFC 3-470-01 Utility Monitoring and Control System (UMCS) Front End and Integration

s. UFC 4-010-05 Sensitive Compartmented Information Facilities Planning, Design, and

Construction

t. NFPA 90A Standard for the Installation of Air-Conditioning and Ventilating Systems mailto:marcus.c.ballnath.ln@usace.army.mil mailto:desiree.n.boger@usace.army.mil mailto:daniel.r.hilgendorf@usace.army.mil mailto:reemt.j.pauw.ln@usace.army.mil

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Observations

The following paragraphs detail the observations made during the site visit on 1 November 2019.

Building 2324 Observations

General Facility Description

Building 2324 is a secure facility with server rooms that require minimal interruption to service.

The main entrance to the facility is located on the north facade. The building is split from east to west; the south half is formed by the original structure and the northern half is the circa 2005 addition. The eastern half of the building and all of the rooms along the back wall are comprised of offices and conference rooms. The three server rooms occupy the western half of the building. The very western edge of Building 2324 is occupied by DPW and is outside the scope of this report and subsequent project.

All roof-mounted mechanical equipment is located on the roof of the addition and not on the original structure.

Room 106A contains the only centralized control panel for the facility which is for the DOAS supplying rooms 106 and 108. The information available and the functionality of the control panel is extremely limited and the room where located is very small and difficult to work in.

There is no overarching BMS for this facility.

Administrative Area

Each of the office and conference rooms have supply air diffusers and return air grilles, and recessed ceiling split-unit cassettes. All of the rooms have hot water radiators for heating and the user reported no issues with the heating system.

The air handler for this system is on the roof of the addition and is designated as equipment group 6 on Illustration 1.

The ceiling mounted cassettes are all connected to Daikin variable refrigerant volume (VRV) condensers located next to the air handler, and are labeled equipment group 5 on Illustration 1.

There is also a condenser for a Daikin split-system on the south façade of the building (located at equipment group 7) which appears to serve room 118.

Conference Room 107

During the site visit the user explained that conference room 107 had several problems. The biggest issue is that the unit does not have sufficient capacity which renders the room unusable.

In addition the unit has had several condensation problems which has caused visible damage to the ceiling of that space.

Server Room 127

This is the largest server room in the facility at 324 sq. meters (3,491 sq ft.). It can hold up to 111 racks supporting different agencies and information sensitivities. It is equipped with uninterruptable power supply (UPS) consisting of three battery units that can maintain power for 25 minutes. In addition to the UPS there is a generator that can run for at least 50 hours.

Interior Equipment

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Room 127 has raised access flooring and underfloor air distribution for the eight computer room air handler units. The CRAH units are spaced evenly along the north and south walls with four units per side. The return air intake is open to the room at the top of the unit and the supply air is distributed under the floor and enters the room through perforated tiles. The total cooling capacity is 416 kW.

Major problems were observed in this room. In general the room was too warm and did not satisfy the temperature requirements of data centers. Many of the units were not running at all and the ones that were had many alarm notifications. At least one of the operating units shows supply air temperature (25.7 degrees C) that was warmer than the return air temperature (23.7 degrees C). Both of those temperature are higher than the UFC requirement for data centers.

During the site visit several of the floor tiles were removed and it could be observed that there was significant pressure underneath the floor, however there seemed to be large temperature gradients and when standing above the perforated tiles there was minimal air flow. There was also no containment throughout the room to ensure the supply air reached the data racks at the designed temperature.

The user also noted that one of the units had three new compressors installed in 2016.

Exterior Equipment

The eight interior CRAH units reject their heat to eight air cooled condensers on the exterior of the north wall of Room 127, labeled as equipment group 1 on Illustration 1. The units were observed to be nearing the end of their service life.

Server Rooms 106 & 108

Interior Equipment

The remaining two server rooms are 106 and 108. Room 106 is the smaller of the two at 35 sq.

meters (378 sq. ft.). This room has two supply air ducts with diffusers and two chilled water in-row coolers with 43 kW cooling capacity. The temperature of this room was acceptable during the site visit.

Room 108 has an area of 187 sq. meters (1,973 sq.ft.) and contains 24 chilled water in-row coolers (4 rows with 6 coolers per row) each with a cooling capacity of 43 kW. The interior temperature of this room was in an acceptable range during the site visit.

Exterior Equipment

The chilled water from rooms 106 and 108 are served by three Carrier air-cooled chillers on the roof at the northwest end of the addition (equipment group 2 on Illustration 2). These rooms are also served by an Exhausto dedicated outdoor air supply (DOAS) unit with heat recovery (See Photograph 10) and a Cabero free cooler/economizer (See Photograph 11).

During the site visit both the economizer and the chillers appeared to have unaddressed maintenance issues with various components in disrepair (See Photo 12). The user noted problems with the equipment: 1) the chillers will operate when outdoor temperatures are -5 degrees C, which is a condition that should utilize the economizer, 2) Only one chiller operates and it is always the same one which indicates control issues as the lead/lag status of the equipment should be changing as well as the number of chillers in response to the load conditions, 3) New glycol is being added to the system every six months which indicates equipment malfunction.

The Exhausto unit appears to be in good operating condition.

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Miscellaneous Remaining Equipment

During the site visit there were other pieces of equipment observed that were not explicitly clear what areas of the building they were serving. These are designated as equipment groups 8, 9, and 10 on Illustration 1.

Equipment Group 8

At this location there are two Cabero air-cooled chillers in a secure fenced area on the southwest corner of the facility. The equipment capacities of the chillers are unknown as the fence prevented getting close enough to read name plate information. It is unclear what area of the building these units are serving. The assumption was that these belong to DPW.

Equipment Group 9

At this location there is one Mitsubishi split-system condenser with 2.9 kW cooling capacity. It is not known which area of the facility is served by this equipment, but assumed to belong to

DPW.

Equipment Group 10

At this location there are four Daikin VRV condensers. The area served by this equipment is unknown. Based on the location it is assumed to belong to DPW.

Conclusions and Recommendations

Conclusions

The existing design and capacity of the HVAC systems for Building 2324 are insufficient for the needs of EUCOM-DIA. The design results in situations inefficient, difficult to maintain and operate, and does not meet the UFC requirements for a critical data center facility.

Building 2324 lacks the required equipment to effectively deliver the mission. There is not an effective means of equipment control for the facility and there are so many systems and individual pieces of equipment that maintenance issues are insurmountable. There is an abundance of space on the roof and the ground level of the facility to provide an improved design for a cohesive building system.

A summary of all observed deficiencies and correlating recommendations are presented in Table 1 – Summary of Equipment Observations and Recommendations.

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Appendices

Table 1 – Summary of Equipment Observations and Recommendations

Equipment Area Equipment Type & Observation Recommendation

Eight air-cooled condensers serving the CRAH units in Room 127. Equipment appears near end of service life and is not providing Room 127 with sufficient cooling capacity.

Remove all HVAC equipment from this area and provide new system compatible with building wide BMS.

Three Carrier chillers. Various unresolved maintenance issues and critical problems with control: e.g. Only one chiller that operates, not using economizer, etc.

Remove all HVAC equipment from

Cabero free-cooler/economizer. Various maintenance issues unresolved. Unit needs frequent additions of glycol which indicates performance issues.

Investigate this unit further to identify if possible to use with new HVAC equipment. If not, remove all existing equipment from this area and provide new system compatible with building wide BMS.

Exhausto dedicated outside air supply unit in good operating condition. Provides ventilation air to Rooms 106 and 108.

Unit to remain in operation and used in conjunction with new equipment.

Five Daikin VRV condensers serving the administrative areas.

Remove all HVAC equipment from

Robatherm air handler serving administrative areas.

Investigate this unit further to identify if possible to use with new HVAC equipment. If not, remove all existing equipment from this area and provide new system compatible with building wide BMS.

Daikin split-system condenser installed in 1997. Potentially serving room 118.

Remove all HVAC equipment from

Two Cabero air-cooled chillers in fenced area with unknown capacity. Potentially belong to

DPW.

Determine owner of this equipment and the space(s) served. If owned by DPW this equipment is out of scope.

Mitsubishi split-system condenser. Area served not known.

Determine owner of this equipment

Four Daikin VRV condensers of various installation years. Areas served not known

Determine owner of this equipment

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Photographs

Photograph 1 – Three Carrier Air Cooled Chillers

Photograph 2 – Alternate View for Carrier Chillers

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Photograph 3 – Carrier Chiller Unresolved Maintenance Items

Photograph 4 – Cabero Free Cooler/Economizer

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Photograph 5 – Exhausto DOAS and Cabero Economizer

Photograph 6 – Administrative Area VRV Condensers

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Photograph 7 – Administrative Area VRV Condensers and Piping

Photograph 8 – Administrative Area VRV Condensers Maintenance Item

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Photograph 9 – Administrative Area AHU

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Figures

Figure 1 – List of Mechanical Equipment by Grouping Number

Exterior Mechanical Equipment

Grp Equipment Type Qty Capacity Brand

1 VRV Condensing Units 4

33.5 kW Daikin

12.5 kW Daikin

12.5 kW Daikin

12.5 kW Daikin

2 Air-Cooled Condensers 8 52 kW (each) WeissTechnik

3 Air-Cooled Chillers 3

350 kW Carrier

350 kW Carrier

350 kW Carrier

4 Chilled Water Economizer/Free cooler 1 700 kW Cabero

5 Ventilation Energy Recovery Unit 1 700 m3/Hr Exhausto

6 VRV Condensing Units 5

28 kW Daikin

28 kW Daikin

33.5 kW Daikin

45 kW Daikin

45 kW Daikin

7 AHU w/ condenser 1 TBD Robatherm

8 Split-System Condenser 1 4.5 kW Daikin

9 Air-Cooled Chillers 2 TBD Cabero

10 Split-System Condenser 1 2.9 kW Mitsubishi

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Illustrations

Illustration 1 – Existing Mechanical Equipment Locations