Madeira City Schools Madeira, Ohio. HVAC Assessment. December 2011 (Revised February 2012)
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1 Madeira City Schools Madeira, Ohio HVAC Assessment December 2011 (Revised February 2012) Prepared by: CMTA Engineering Consultants, Inc Meeting Street Prospect, KY (502)
2 Table of Contents Executive Summary... Page 2 Board Office and Existing Boiler Plant... Page 3 Guidance Office/Media Center/Classrooms... Page 5 Auxiliary Gyms... Page 8 Drawings MSK-01: Scope of Work Reference Drawing Madeira High School HVAC Assessment Page 1 of 8
3 Executive Summary As a follow-up to the recently completed Phase 1 and Phase 2 Energy Use Reduction and Efficiency Improvement projects undertaken by Madeira City School System for their Elementary, Middle and High School facilities this assessment has been prepared to address possible improvements to ancillary areas around the High School campus. In particular, the aging Hot Water Boiler, Chilled Water system and Air Handling equipment serving half of the Board Office Building, the Guidance Office near the Media Center, the Media Center and two adjacent classrooms and the Auxiliary Gyms are to be considered. The goal of this assessment is to identify options to reduce energy consumption, replace aging equipment and reduce maintenance in the areas of the High School campus noted above. Site investigations of the existing facilities have been conducted and recommendations discussed on site with the Madeira staff. Initial recommendations consisted of lower cost and higher cost retrofits with good efficiency gains. These recommendations have been finalized into a list of solutions which are summarized in the following pages. This assessment contains an examination of the HVAC systems serving these areas on an area by area basis in order to quantify and compare the different options available for renovation. There exists potential across the High School campus at various locations for the installation of a geothermal well field to serve the areas being considered as a part of this assessment. Similar to the previous Phase 2 project recently completed at the Commons Building on the High School Campus, this option will be explored for each of the areas assessed in the following report for feasibility and for comparison with traditional systems. Madeira High School HVAC Assessment Page 2 of 8
4 Board Office and Existing Boiler Plant Existing Mechanical Systems The Board Office for the Madeira City School system is located on the campus of Madeira High School and also houses the Hot Water Heating Boiler Plant for the campus. Half of the building was recently renovated; however, the other half of the building s HVAC system is in need of replacement. There is approximately 2,500 square feet of office space currently served by a Rooftop Air Handling Unit (RTU) that is past its expected life. The Boiler Plant consists of three boilers and two circulating pumps. Two of the boilers are Thermal Solutions 80-85% efficient boilers (only one of which is operational) and are approximately 11 years old while the third is a large water-tube boiler that appears to be original to the building and 30+ years old. These boilers serve the fin tube heaters along the perimeter of the Guidance Office, the Media Center, the classrooms next to the Media Center and the Auxiliary Gyms. The controls on the Boilers were recently replaced during the construction Phases previously completed from pneumatic to DDC, however, there is still a controls air compressor within the space that needs to be demolished once all equipment served by the existing Boiler Plant is demolished and replaced. The two hot water pumps are rated at 15 hp each and circulate Hot Water to the various parts of the campus where Hot Water is required for heating. There is a significant amount of piping in the boiler room and across the campus that is missing or has damaged insulation. Replacement Mechanical System Options and Costs For the Board Office areas (which include the Boiler Room, Shop Area and adjacent hallway) it is recommended that the existing RTU unit on the building be replaced with a new packaged DX RTU that also contains gas heat. This new unit would be provided with DDC Controls that are compatible with the existing SIEMENS Building Automation System (BAS). The unit would be a Variable Air Volume (VAV) unit that would allow for individual space control in the office areas below by providing a separate VAV box with electric heat and thermostat for each space served by the unit. Since the unit is a DX unit with gas heat it will be able to heat and cool the areas served independently of the other systems across the campus. The existing Boiler Plant that serves the areas being considered within this assessment has seen its use significantly reduced as a result of the renovations to the High School Campus over the last decade. With the installation of the geothermal system for the Commons Building and the gas-fired rooftops used across the Classroom Wings, much of the heating load originally required of the plant has been eliminated. Because of this issue, it is recommended that the existing Boiler Plant be replaced with new Boilers and Pumps sized to only accommodate the remaining systems requiring hot water. The existing gas service entry is also within this area, with a meter that is much larger than is required at this time. It is recommended that this meter be replaced and the gas meter entry loop be reworked regardless of what is done with the Boiler Plant. Madeira High School HVAC Assessment Page 3 of 8
5 With a geothermal well-field available for the heating/cooling needs of half of the Board Office, a water source RTU could be located on the roof to serve the office areas below. All of the other features present with the traditional DX/gas equipment considered above would be present. If a RTU is not desirable, floor mounted Heat Pumps similar to those installed within the Commons Building are also a possibility. These units could be installed within the demolished Boiler Room. If a well field is accepted as the solution for the spaces being considered in this assessment, it will be located in an area that allows for future expansion to serve other existing spaces. The following are the options presented and their approximate costs. These costs include the demolition and removal of all existing equipment being replaced, as well as the cost of all new equipment and labor required for the renovation. For options considering the use of a geothermal well field, the cost provided includes the material cost and labor associated with the terminal equipment as well as the installation of a well field to serve this area. Mechanical System Option Estimated Cost DX VAV RTU $35,000 Geothermal VAV RTU $50,000 Demolish Boiler Plant $15,000 Replace Existing Gas Meter/Rework Piping $10,000 *Installation of a geothermal system in this area would result in an approximately $15,000 premium over a conventional system. This translates into a potential payback of 5-10 years. Madeira High School HVAC Assessment Page 4 of 8
6 Guidance Office/Media Center/Classroom Areas Existing Mechanical Systems The Guidance Office is approximately 1,800 square feet and is served by an existing Chilled Water RTU with perimeter fin tube radiant heaters that are served by the Boiler Plant within the Board Office. There is a 40 Ton Split Chiller outside of the building within the courtyard that is paired with an evaporator barrel located in the Mechanical Room beside the Media Center. Removal of the Chiller from this area of the campus has been requested, as the courtyard area nearby is unusable from an acoustical and aesthetic standpoint with it present. The Media Center and its associated support spaces are approximately 5,000 square feet in total and are served by an existing Multi-Zone Air Handling Unit (MZU) located in an adjacent Mechanical Space. This Mechanical Space also houses the Air Compressor for the remaining building Pneumatic Controls and the Evaporator Barrel for the Split Chiller located outside the Guidance Office. The existing MZU is equipped with a Chilled Water (CW) and Hot Water (HW) coil for space conditioning within the Media Center and its associated spaces. In addition to the equipment replacement that will ultimately be a part of the work within this space, the air distribution within the space also needs to be improved. Currently, all of the supply air from the MZU into the Media Center is supplied from wall grilles along one of the four walls of the Media Center resulting in the supply air being blown across the Media Center while it is returned through a few ceiling return grilles within the space. The two Classrooms adjacent to the Media Center along with the office across the hall are currently served by the MZU located within the Mechanical Room beside the Media Center. Due to the varying occupancies and use of the Classrooms and Office compared to the Media Center it is desired by Madeira that this assessment explore how to serve them independently. These spaces represent approximately 1,700 square feet. Replacement Mechanical System Options and Costs A new DX RTU with gas reheat is the recommended option for a conventional system replacement to serve the Guidance Office. This unit would be a VAV unit with VAV boxes assigned to each zone below and its associated thermostat. This installation would mimic the other RTU installations around the High School campus and would be installed with DDC controls capable of communicating with the existing BAS. The existing fin tube radiant heaters would be removed, along with all of the associated hot water piping, further reducing the heating load demand on the Boiler Plant in the Board Office. The existing Chiller serving the existing RTU and the Media Center MZU would also be removed with this option (along with the options detail below for the Media Center.) This would allow for development of the Courtyard area outside of the Guidance Office and the Media Center. In renovating the existing Media Center, there are two options utilizing conventional DX/Gas heat equipment available. One option uses an interior, floor set Air Handling Madeira High School HVAC Assessment Page 5 of 8
7 Unit (AHU) configuration that would be installed in the same location as the existing MZU, the other option is a packaged rooftop RTU configuration. With the interior AHU option, the DX Coil would be paired with an external Condensing Unit (CU) mounted on the roof of the Mechanical Room. Both of these options would utilize a VAV system, VAV boxes with electric heat and individual thermostats for the different zones within the Media Center Areas. The ductwork and VAV boxes served by either unit would be located above the ceiling of the Media Center which will require some ceiling removal and reinstallation. A low return grille along the wall of the Media Center adjacent to the Mechanical Room would also be installed to assist in air movement through the space. With the RTU option, floor space within the existing Mechanical Room would be reclaimed for other purposes, while the interior AHU option would seek to reuse the existing space occupied by the outgoing MZU. Both options presented allow for the Chiller beside the Guidance Office to be demolished by installing packaged DX equipment in lieu of the existing split DX design. A new DX RTU with gas reheat is the recommended option for a conventional system replacement to serve the Classrooms and the Office across the hall. This unit would be a VAV unit and VAV boxes with electric heat assigned to each zone below and its associated thermostat. This installation would mimic the other Classroom RTU installations around the High School campus and would be installed with DDC controls capable of communicating with the existing BAS. With a geothermal well-field available for the heating/cooling needs of the Guidance Office, Media Center and adjacent classrooms, there are several options available for space conditioning. In the Guidance Office, a water source RTU could be located on the roof to serve the office areas below. All of the other features present with the traditional DX/gas equipment considered above would be present. If a RTU is not desirable, floor mounted Heat Pumps similar to those installed within the Commons Building are also a possibility. These units would be installed in a space to be determined within the Guidance Office and would require similar floor space to the heat pump closets added in the previous renovation. In the Media Center, the options of a water source RTU or an interior water source AHU are available, but there is also opportunity for the use of smaller heat pumps. The larger equipment would involve VAV equipment and VAV boxes with electric heat and ductwork installed in the same manner as described above, however, with heat pumps the distribution would be on a zone by zone basis with a unit paired to each zone. The Media Center itself would be served by at least two units while the support spaces would require an additional heat pump. These heat pumps could be located in the existing Mechanical Room or space not yet allocated for mechanical equipment somewhere within the Media Center and its associated spaces. Similar to the classrooms in the Commons Building, the Classrooms adjacent to the Media Center could be served by their own water source heat pumps. Depending upon how the Media Center is ultimately renovated, there exists potential for heat pumps serving these areas to be located within the existing Mechanical Room beside the Media Center provided the MZU there is removed. If this space is not available, heat Madeira High School HVAC Assessment Page 6 of 8
8 pump closets similar to those installed within the Classrooms in the Commons Building would need to be constructed within the spaces. The following are the options presented and their approximate costs. These costs include the demolition and removal of all existing equipment being replaced, as well as the cost of all new equipment and labor required for the renovation. For options considering the use of a geothermal well field, the cost provided includes the material cost and labor associated with the terminal equipment, as well as the well field itself. Mechanical System Option Estimated Cost DX VAV RTU s/ahu s (All Areas) $120,000 Geothermal RTU s/ahu s/heat Pumps $170,000 *Installation of a geothermal system in this area would result in an approximately $50,000 premium over a conventional system. This translates into a potential payback of years. Madeira High School HVAC Assessment Page 7 of 8
9 Auxiliary Gyms Existing Mechanical Systems The existing Auxiliary Gyms at the High School are currently served by Heating and Ventilation (HV) units only they are not air conditioned. These units are served by the existing Boiler Plant within the Board Office, with two units supported from the structure in the older of the two Gyms and a floor set unit within a Mezzanine serving the newer Practice Gym. There is also an existing Mechanical Space within the Gym area that houses the pumps and controls serving the Hot Water distribution system in the Gym. It is recommended that once the Boiler Plant within the Board Office is demolished, a new stand alone Boiler be installed within the Gym area to serve its heating needs. There are also numerous issues with the envelope in this area that includes old, leaky roof openings that have been inadequately patched as well as poor or missing seals around exterior doors. Replacement Mechanical System Options and Costs For the Gym areas, a different approach to replacement of the existing equipment has been considered when compared to the other areas discussed within this assessment. Due to the fact that these spaces are currently not air conditioned - and it is not desired that this capability be added at this time an upgrade to the heating capacity of the existing equipment is all that is desired. With all of the other options considered above, the existing Boiler Plant within the Board Office is to be demolished. Once this occurs, a new heating source for the Gym area units will be required. There exists floor space (identified with Madeira during the walkthrough) for a new Boiler to be located to serve this existing equipment. In addition to the purchase and installation of a new stand-alone Boiler for the Gym area and its associated controls, the existing HW distribution equipment located within the Gym area is also at the end of its useful life. Because of this, it is recommended that the existing pumps, controls, etc. that serve to provide hot water to the existing HV units be replaced with new equipment and controls while installing the new Boiler. Further still, existing deficiencies in the building envelope in the area of the Gyms can also be addressed during the renovation through the installation of new exterior doors, the insulating and sealing of existing leaky roof penetrations, as well as the replacement of worn out gravity dampers on existing relief hoods above the Gyms. Mechanical System Option Estimated Cost New Boiler for both Gym Areas $100,000 Envelope/Infiltration Upgrades $25,000 Madeira High School HVAC Assessment Page 8 of 8
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