Ross Parkman PE Ryan Wester PE

Ross Parkman PERyan Wester PE

Central Chiller Plant Experience

Big Ten and Friends Mechanical and Energy Engineering ConferenceOctober 1, 2013

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Discussion Topics• Planning• Design• Project Delivery and Construction• Commissioning and Startup• Operations• Q&A

Facilities Operation and Development

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Significant Planning Milestones• Feasibility Study Med Center Chiller Plant June

2004• Campus Infrastructure Master Plan

March 2006• Preliminary Design and Cost Estimate

Sept 2006• Additional Studies and Value Engineering

Redesign option for “Building Loop”Planning/design New Bed Tower and Existing Hospital HVAC UpgradesFeasibility Study/Life Cycle Cost for “Building Loop” vs. Central Plant

Plant Site Studies (W of Cannon / 10th Ave, W of Cannon / E of Cannon)

• A/E and Construction Manager Contracts Aug2009

• Program of Requirements Oct 2009

• Estimate of Probable CostNov 2009


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Key Project Dates• Chiller Order (6 @ 2500 tons) June 2010• Construction Start January

2011• Initial Equipment Testing May

2012• “Construction” Chilled Water August 2012• “Reliable” Chilled Water October 2012 • 2 Additional Chillers

December 2013

Plant Statistics• 20,000 tons initial plant capacity (5000 tons on standby generators) • Awarded LEED Silver by USGBC• 10,000 tons future expansion• Free cooling future addition


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Design and Project Delivery• Tunnel and distribution piping designed and constructed as

part of Med Center Expansion Project • Building Exterior Design by Signature Architect • Local Architect of Record and Engineering Team

• Controls integrator on A/E team• Design and building modeling with Revit

• Chillers selected and direct purchased through State of Ohio Term Contract

• Active input by OSU Utilities (McCracken Chiller Plant Experience)

• Commissioning Agent


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Design and Project Delivery (cont.)• Utilized Construction Reform opportunity:

• State of Ohio designated 3 demonstration projects for Construction Reform• Medical Center Expansion including Chiller Plant was identified as the

“LARGE” demonstration project• A modified project delivery method was applied utilizing “Design Assist”

by the following contracting specialties• Mechanical, Electrical, Structural, Concrete

• Design assist contracts established with Guaranteed Maximum Pricing (GMP)

• Construction Coordination Model in Navisworks with Construction Manager as lead

• Included all equipment, steel and pipe and conduits (>=2 inch diameter)• Resolved all interferences• Produced shop fabrication drawings


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Design and Project Delivery (cont.)• Distribution Tunnel to new Tower and 5 existing buildings,

Cast in place concrete 10’ x12’42” to 36” welded steel chilled water supply and return pipe12” inch seamless steam pipe6” 316L stainless steel condensate pipeValve vaults and provision for future building connections

• Chilled Water DistributionDirect buried HDPETransition from HDPE to welded steel in four valve vaults

• Primary/Secondary Pumping with Plate and Frame Heat Ex.

Primary pumps maintain chiller and positive bridge flow Secondary building pumps maintain flows for building temperature control


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Project Delivery Method Key Benefits• System designed to match pre-purchased chillers• Design Assist under GMP provided an effective process for

equipment evaluation/selection and value engineering • Model review and update meetings insured construction was

coordinated and stayed on schedule• Modeling eliminated rework of shop fabricated piping due to

interferences• Common commissioning agent for both Plant and Building

Systems


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3D BIM Construction Model of #1 Chiller(Navisworks)

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Installation of chillers 1 - 6

on second floor of the plant

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Inspections• Construction

Structural steel and concreteUT weld examinations: steam, chiller water and condensate pipingHydrostatic testsA/E as Contract AdministrationConstruction Manager

• Final InspectionsODIC

<=480 volt electrical Building systemsLife Safety

OSU Utilities (as AHJ) 575V and higher electrical Instrumentation and control wiring Process piping and equipment


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Equipment Readiness • Mechanical

Vendor/Contractor startup supportPipe flushing with system pumps at 7-9 fps, (chiller tube bundles

bypassed)Frequent startup strainer cleaning Metal passivation and chemical treatment systems

• Electrical Vendor/Contractor startup supportPhase checksRelay and wiring checkout

• ControlsField instrument calibration and verification Point to point zero and span check 134 field devices, one time,

complete through to the graphical interfaceVerified wiring, communication and graphical displays for 3500 total

points .


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Site Acceptance Testing (SAT) and Commissioning • Hydraulic flow testing of distribution loop (chiller plant & bldg. pumps) • Systematic test and verification of all Control Sequences

Condenser Pumps, Cooling Towers, Chiller Water Pumps, ChillersTested chillers with “warm” loop water prior to building conversions

• Go liveBuilding chillers kept as backup for two weeksMidnight conversion of first two buildings (8/17/12 and 8/24/12)Initial testing and controls tuning completed by 7:00 AM

• Reliable Chilled Water/Backup GeneratorsTested load share with utilityControlled load assumptionFull Black Start TestThird building conversion (10/16/12)


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Operating Results• Med Center reports improved building temperatures and chilled

water system reliability• Plant operates on full automatic

Four daily walkthroughs for equipment checks and water quality testing

Towers and chillers stage on and off to satisfy building cooling needs• Metrics

0.76 kw/ton (central plant only, range 0.72 to 0.78) 17% (preliminary) net reduction in campus electricity for central

chilling 98% of production metered and billed at buildings$3800/ton initial build (with standby generation)$2950/ton final build out (estimated)Some increase in net building utility costs but with improved

service levels


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Questions?

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Thanks to the Project Team!


Ross Parkman PE Ryan Wester PE

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