Old Jail HVAC Replacement Feasibility Report

Transcription

1 Old Jail HVAC Replacement Feasibility Report Madera, CA Prepared by Kitchell for the County of Madera, California Job No. 6168A3

2 Executive Summary On October 21, 2016, Kitchell conducted a Feasibility Assessment of built in 1988 to determine the best approach for replacement of the old Jail HVAC system and related electrical equipment. The existing Jail mechanical equipment comprises of air-cooled chillers, boilers, air handlers, and domestic hot water heaters that are original to the Facility, and all of the equipment is beyond its useful life even though it has been well maintained. At present, the system has difficulty maintaining interior comfort levels during high and low seasonal loads. The pneumatic HVAC controls system is obsolete and does not communicate with the County s web based Alerton controls system. In 2013, construction was completed on the Jail Expansion adjacent to the old Jail. This expansion included a centralized physical plant (Central Plant) that serves the mechanical and electrical systems of all Jail expansions (including Central Kitchen/Laundry completed in 2016). The Central Plant building shell was sized for additional mechanical equipment to support modernization of the HVAC systems at the old Jail in the future. The piping infrastructure comprises of supply and return lines for chilled water, heating water, and domestic hot water lines which is now in-ground up to the face of the old jail and was designed for extension into the building. The current HVAC and electrical equipment in the Central Plant only supports the connected systems in the 2013 Jail Expansions and the 2016 Central Kitchen/Laundry. The Central Plant does not have the capacity support mechanical loads for the new equipment serving old Jail. Kitchell s recommendations are as follows: 1. Replace the air handlers in kind. There will be no change in the present served areas of each air handler. The air handlers are located inside the building with no large openings for unit replacement. The air handlers will need to be assembled from smaller components that fit the existing man doors and certified by engineers in place. It is reasonable to assume that a one for one replacement of the associated motor control center [480/277V, 1200A] will suffice. 2. Remove three existing roof mounted air-cooled chillers and connect the air handlers on two additional 175 ton centrifugal chillers in Central Plant building. It is reasonable to assume that the associated motor control center [480/277V, 600A] will be upsized to 1000A. Repair the roofing membrane as needed. 3. Install additional cooling tower of 350 tons in the mechanical yard of the Central Plant and connect to the chiller system of the plant. It is reasonable to assume that the associated motor control center [480/277V, 600A] will be upsized to 1000A. 4. Remove existing boilers from each three old Jail mechanical rooms and connect the air handlers on two new 860 MBH boilers with two 800 gallons storage tanks in Central Plant building. It is reasonable to assume that the associated motor control center [480/277V, 600A] will be upsized to 800A. A - 1

3 5. Remove the existing domestic hot water heaters from each three old Jail mechanical rooms and connect existing distribution piping of the old jail with piping to Central Plant. Provide two additional domestic water heat exchangers of 560 MBH in Central Plant building. It is reasonable to assume that the associated motor control center [480/277V, 600A] will be upsized to 800A. 6. Replace the existing pneumatic HVAC controls in the old Jail with Direct Digital Controls system in locations to be determined. 7. The new Central Plant piping risers must be located on the exterior face of the wall to avoid impacting the central corridor of the old Jail and covered with concrete masonry units to match existing so as to prevent hand holds or abuse. Lateral runs of the piping to the respective mechanical rooms could be located over the hard lid above the second floor central corridor and under the sheet metal roof. 8. It is not known when financing can be secured for this project. Potential construction schedule issues is the expansion of the central plant. The preparation time for submittals, lead time for equipment procurement, delivery, and installation will likely run into the summer. It may be possible connect the replacement air handlers with the current Central Plant equipment in the short term. Otherwise temporary cooling of 12,240 square feet of old Jail spaces should be provided if construction of the critical components extends into the cooling season. A - 2

4 I. General Facility Description Located at Rd 28, Madera, CA 93638, the was originally built in 1988 of one and two stories in height and totaling 102,590 square feet (SF) in area. It was expanded in 2013 with attached support services and Inmate Housing buildings totaling 30,440 SF, and separated buildings for Visitation/Training (12,240 SF) and Central Plant (2,400 SF). Another addition for Central Kitchen and Laundry was completed in In September of 2016, Madera County requested Kitchell to provide design services for refurbishment of the old jail HVAC system. In preparation of the design work, this feasibility assessment was commissioned to determine the best approach for design. A field review was performed on October 21, 2016 with County Capitol Projects representative Maritza Rodriguez and Facilities Maintenance supervisor Raymond Huerta present. The original jail has three separate cooling towers and related air handlers which are original to the building. Air handlers for C/D and E/F/G/K Housing Modules are located in second floor mechanical rooms - that for the A/B Modules is in a penthouse on the roof. All of the jail additions built in this A - 3

5 decade are presently serviced by the central plant, and the plant has roughed in underground services in the rear yard for connecting new air handlers in the old jail. II. Site A. General 1. The existing landscape around the facility appears to be well maintained and no drainage issues was reported to the team. 2. An area of the rear yard outside and adjacent to Central Control has been excavated and the end points of the central plant piping rough-in was visible. Moderate corrosion on the valve and pipe was seen. III. Building A. Architecture 1. Roof a. The roof consists of built up roofing membrane with gravel ballast that is original to the building. The roofing is in fair condition but beyond the useful life of the membrane. No roof leaks is reported. b. A metal panel roof covering the second floor central corridor is in good condition. No visible fading of the finish was observed and no leaks have been reported to the assessment team. Below the metal roof is concrete topped metal deck of which the underside can be seen inside the corridor. On review of the structural drawings, the roof is supported by a welded metal angle frame and it affords approximately 5-3 head clear under the frame at the top apex of the roof. Presently, there is no access to this roof plenum space for verification. 2. Exteriors a. The building s exterior is fully grouted concrete masonry walls and is in good condition. The exterior walls of the old jail are twelve inch insulating concrete masonry units, with an eight inch wide structural core. 3. Interior a. The second floor central corridor was originally the public access corridor to the non-contract visitation rooms in the housing buildings. With public access by video visitation in the Visitation building, the corridor is now for staff use only. There are security electronic racks and conduit runs inside the corridor. b. Ceiling height of the second floor central corridor is 8-8. A measurement of 1-5 was made from the underside of the suspended acoustic ceiling to the underside of structural deck above. This is a deviation from the as-built drawings where ceiling was shown 2-0 below the deck. The current ceiling plenum height is inadequate for any future HVAC piping runs. B. Mechanical 1. Heating, Ventilating, and Air Conditioning a. The existing rooftop air-cooled chillers, boilers, and ancillary equipment serving the housing units are past their useful life and have experienced difficulties maintaining load during peak cooling and heating months. The existing rooftop air-cooled chillers and boilers should be removed and Chilled Water (CHW) and Heating Hot Water (HHW) service should be provided by the Central Plant. The benefits of having CHW and HHW supply from the A - 4

6 Central Plant include having greater efficiency and chiller and boiler maintenance in a centralized location. b. The HVAC controls system consist of pneumatic actuators, air compressor, and pneumatic controls panel. This control system is past its useful life. The controls system should be upgraded to a new Direct Digital Controls (DDC) system. By upgrading the controls system, the air handlers will be accessible through the county-wide Alerton controls system. c. The six air handlers serving the housing units are past their useful life. The air handlers consist of two 45-ton units, one 40-ton unit, and three 30-ton units. Although the air handlers are well maintained and operable, it is recommended that they be replaced. d. The Central Plant chilled water system consist of two 175-ton centrifugal chillers and matching cooling tower. The Central Plant design allows for the expansion of two additional 175-ton chillers. The Central Plant s current chilled water capacity of 350 tons will not be able to support the current connected load and the proposed load of the three housing units. It is recommended to increase the Central Plant s chilled water capacity by adding an additional chiller, cooling tower, and the required ancillary equipment. e. The Central Plant heating hot water system consist of three 860 MBH boilers. The Central Plant design allows for the expansion of three additional 860 MBH boilers. The Central Plant s current heating hot water capacity of 2,580 MBH will not be able to support the current connected load and the proposed load of the three housing units. It is recommended to increase the Central Plant s heating hot water capacity by adding additional boilers and required ancillary equipment. C. Fire / Life Safety Protection Systems 1. Fire Protection a. Portable fire extinguishers are present in the building. 2. Fire Alarm a. The building is equipped with a Simplex 4100ES Fire Alarm Control Panel that is located in an electrical room within the chiller room. Various detection and notification devices are located throughout the jail. Overall, the system appeared to be in good condition and there were no issues reported by maintenance personnel. D. Electrical 1. Electrical Supply and Distribution a. The main switchboard is located in the outdoor utility year and is rated 4000A at 480/277V, 3 phase, 4 wire. The main switchboard is not original to the jail and is in good operational condition. b. A second switchboard is located in Electrical Room 204 and is rated 2000A at 480/277V, 3 phase, 4 wire. This switchboard has exceeded its industry rated useful life and should be replaced. c. The emergency switchboard is rated 600A at 480/277V, 3 phase, 4 wire. Its corresponding automatic transfer switch is also rated 600A at 480/277V. Both the emergency switchboard and its automatic transfer switch have exceeded their industry rated useful life and should be replaced. Also, both are located in Electrical Room 204. A - 5

7 d. Several panelboards, excluding Panel CP, are approaching their industry rated useful life and should be replaced. Of these panels, Panel LC [rated 200A at 120/208V], Panel LCE [rated 100A at 120/208V], Panel HC [rated 225A at 480/277V] and Panel HCE [rated 225A at 480/277V], were identified in the C/D Equipment Room. Further, Panel LF2 [rated 100A at 120/208V], Panel LFE [rated 100A at 120/208V], Panel HF [rated 225A at 480/277V] and Panel HFE [rated 225A at 480/277V], were identified in the E/F Equipment Room. Panel CP is not original to the jail and is in good operational condition. e. There are various transformers, excluding Transformer TCP, that are approaching their industry rated useful life and should be replaced. Of these transformers, Transformer TC [rated 75KVA at 480: 208/120V] and Transformer TCE [rated 45KVA at 480: 208/120V], were identified in the C/D Equipment Room. Transformer TEE [rated 45KVA at 480: 208/120V], was identified in Electrical Room 204. Transformer TB [rated 75KVA at 480: 208/120V] and Transformer TBE [rated 45KVA at 480: 208/120V], was identified in the A/B Penthouse. Also, Transformer TF [rated 75KVA at 480: 208/120V] and Transformer TFE [rated 45KVA at 480: 208/120V], were identified in the E/F Equipment Room. Lastly, one 5KVA Transformer is located on each of the HVAC units for Modules C/D and Modules E/F. Transformer TCP is not original to the jail and is in good operational condition. f. There are three (3) motor control centers that have exceeded their industry rated useful life and should be replaced. [(2) 480/277V, 600A and (1) 480/277V, 1200A] g. There are two (2) 800 KW diesel generators with an associated 1600A automatic transfer switch located in the outdoor utility yard. The generators are not original to the jail and are in good operational condition. h. Overall, the jail s original equipment is approaching its industry rated useful life and should be replaced. However, there were no issues reported by maintenance personnel. 2. Interior Lighting a. Interior lighting is provided by fluorescent fixtures. b. All of the fixtures appeared to be in good operational condition and there were no issues reported by maintenance personnel. A - 6

8 Appendix A Building Deficiency Photos The motor control center has exceeded its industry rated useful life and should be replaced. (Note: Typical for all of the jail s original motor control centers.) The panels and transformers in the C/D Equipment Room are approaching their industry rated useful life and should be replaced. (Note: Typical for all of the jail s original panels and transformers. The E/F Equipment Room is similar in arrangement and condition.) A - 7

9 The switchboard in Electrical Room 204 has exceeded its industry rated useful life and should be replaced. Transformer TEE, the emergency switchboard and its associated automatic transfer switch (ATS) are located in Electrical Room 204. The switchboard and its ATS have exceeded their industry rated useful life and should be replaced. Transformer TEE is approaching its industry rated useful life and should be replaced. A - 8

10 The transformers located in the A/B Penthouse are approaching their industry rated useful life and should be replaced. One 5KVA Transformer is located on each of the HVAC units for Modules C/D and Modules E/F. The transformers are approaching their industry rated useful life and should be replaced. A - 9

11 Housing Unit s Boilers are past their useful life. Pneumatic control actuators are past their useful life and should be upgraded to electric actuators. A - 10

12 Appendix B - Statement of Probable Cost See the following pages for the estimated cost to repair the identified deficiencies. A - 11

13 MADERA COUNTY ROM ESTIMATE WORKSHEET PROJECT: JAIL HVAC ASSESSMENT PHASE: CONCEPTUAL ESTIMATE DATE NOVEMBER 7, 2016 REPORT DATE: JANUARY 26, 2017 BID DATE: PREPARED BY: T. PRECHEL UNIT TOTAL ITEM DESCRIPTION QTY UNIT PRICE COST 1 of 2 1/26/2017 9:55 AM 6168 Madera Co HVAC ROM Est xls DEMOLITION REMOVE ROOF TOP AIR-COOLED CHILLERS 3 EA $15, $45,000 REMOVE (E) BOILERS ( OLD JAIL MECH ROOMS) 3 EA $10, $30,000 REMOVE DOMESTIC HOT WATER HEATERS (OLD JAIL MECH ROOM 3 EA $7, $22,500 MECHANICAL 175 TON CENTIFUGAL CHILLERS (AT CENTRAL PLANT) 2 EA $166, $332,500 REPLACE AIR HANDLERS (OPTION B) 45 TON 2 EA $162, $324, TON 1 EA $144, $144, TON 3 LF $108, $324, TON COOLING TOWER (AT CENTRAL PLANT) 1 EA $75, $75, MBH BOILERS, AND 800 GALLON STORAGE TANKS 2 EA $65, $130, MBH DOMESTIC WATER HEAT EXCHANGERS (CP) 2 EA $45, $90,000 DDC CONTROLS 102,590 SF $6.00 $615,540 8 " CHS/R PIPING 1,400 LF $ $190,400 6" HWS/R PIPING 1,400 LF $ $142,800 DHS/R PIPING 1,400 LF $85.00 $119,000 ELECTRICAL REMOVE EXISTING MOTOR CONTROL CENTERS 6 EA $1, $6,000 MOTOR CONTROL CENTER 480/277V, 600AMP 1 EA $11, $11,250 MOTOR CONTROL CENTER 480/277V, 1200AMP 1 EA $17, $17,500 MOTOR CONTROL CENTER 480/277V, 1000AMP 2 EA $15, $30,000 MOTOR CONTROL CENTER 480/277V, 8000AMP 2 EA $13, $26,250 NEW FEEDERS FOR 600A MOTOR CONTROL CENTER 150 LF $ $20,355 NEW FEEDERS FOR 1000A MOTOR CONTROL CENTER (X2) 300 LF $ $66,780 NEW FEEDERS FOR 800A MOTOR CONTROL CENTER (X2) 300 LF $ $54,300 TRENCHING 75 LF $ $7,500 SUBTOTAL HARD COSTS $2,824,675 CONTINGENCY ESTIMATING CONTINGENCY 20.00% $564,935 SUBTOTAL CONSTRUCTION COSTS $3,389,610

14 MADERA COUNTY ROM ESTIMATE WORKSHEET PROJECT: JAIL HVAC ASSESSMENT PHASE: CONCEPTUAL 2 of 2 ESTIMATE DATE NOVEMBER 7, /26/2017 9:55 AM REPORT DATE: JANUARY 26, Madera Co HVAC ROM Est xls BID DATE: PREPARED BY: T. PRECHEL UNIT TOTAL ITEM DESCRIPTION QTY UNIT PRICE COST MARK-UPS GENERAL CONDITIONS 15.00% $508,442 OVERHEAD & PROFIT 12.00% $467,766 INSURANCE & BONDS 3.00% $130,975 SUBTOTAL MARK-UPS $1,107,182 SUBTOTAL CONSTRUCTION COSTS & MARK-UPS $4,496,792 ESCALATION ESCALATION (MARCH 2017) 2.08% $93,683 KCEM ROM ESTIMATE: $4,590,475

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