FAARM-Underground Facility Conceptual Design Review Mechanical Systems Prepared by: Dunham Associates, Inc. April 17, 2012 Dunham Project Number: 0412145-000-00 Dunham Associates Inc. Page 1 of 8
Mechanical Systems A. GENERAL 1. Overview a. This mechanical system design narrative describes the requirements of the mechanical systems for a new underground cavern area of an existing underground cavern located in the either The Homestake Mine in Lead, South Dakota or Soudan Mine in Soudan, Minnesota. 2. Equipment Redundancy a. Equipment shall be defined only for critical equipment systems serving the new clean room areas and back of house spaces. B. DESIGN CONDITIONS 1. Outside Design Conditions: based on composite data from various sites with similar latitude, elevation and longitude as per the 2009 ASHRAE Handbook- Fundamentals: a. Site elevation is -4850 ft below the surface but at 650 ft above sea level (Homestake Mine) or -2341 below the surface and -689 ft below sea level (Soudan Mine). b. Outside Design Temperatures 1. Cooling = 90.8 F db/58.4 F wb 2. Dehumidification = 90.8 F db/59.0 F dew point 3. Heating = -15.5 F c. Ventilation Air (w/drift Air) (Temps defined by SDSTA or Soudan) 1. Cooling = To be determined 2. Heating = To be determined 2. Indoor Design Conditions a. Class 2000 Clean Room 1. Summer = 65 F DB/50% RH 2. Winter = 65 F DB 3. Clean Room ACH = 90 4. Gowning Room ACH = 80 b. Class 10000 Clean Room 1. Summer = 68 F DB/50% RH 2. Winter = 68 F DB 3. Clean Room ACH = 30 4. Gowning Room ACH = 20 c. Back of House Spaces 1. Summer = 70 F DB/50% RH Dunham Associates, Inc. Page 2/8
2. Winter = 70 F DB 3. ACH = 15 d. Mechanical/Electrical Rooms 1. Summer = 80 F DB 2. Winter = 80 F DB e. Process Spaces (Water Purification Rm) 1. Summer = 85 F DB 2. Winter = 85 F DB f. Indoor Air Quality 1. All spaces will be designed to meet ASHRAE 62-2001 standard. 2. Process Spaces will be provided with filtered ventilation air drawn from the adjacent drift. 3. Cooling Load Design Considerations a. Internal Heat Gains 1. Clean Room a. People = 260 BTUH Sens.; 310 BTUH Latent b. Lights = 4 Watts/sq. foot in clean room. 3.0 Watts/sq. foot in gowning area. c. FAARM Appliance = 67.34 KW (Torus) (Equipment diversity allows for 50% of total.) 2. All other spaces a. People = 260 BTUH Sens.; 310 BTUH Latent b. Lights = 2.5 Watts/sq. foot; 80% to space c. FARRM Appliance = 47.08 KW )Per Summary Table For FAARM) 3. Equipment & Process Spaces a. Lights = 1.0 Watts/sq. foot; 80% to space FAARM Appliance = 10 KW (Water Perification Room) (Per Summary Table For FAARM) C. SITE UTLITIES 1. The following will be provided by the site to the entrance of the new facility: domestic cold water, non-potable industrial cold water, sanitary waste (forced main), sanitary vent, hazardous waste, outside ventilation air, smoke exhaust, general and hazardous exhaust, supply and return chilled water and fire sprinkler water. The exact size of each utility main remains unresolved. D. PLUMBING SYSTEMS 1. Potable Domestic Water: a. Potable domestic water will be piped from the 4 utility stub provided at the entrance to the new facility. b. A 50 gallon electric water heater w/domestic hot water recirculator. c. Emergency eyewash/shower units with individual tempering valves (Physics & Chemistry Area, Machine Shop). d. Domestic hot and cold water are required to serve the new lavatories, janitor sink and water closet. Dunham Associates, Inc. Page 3/8
2. High Purity Water: a. Pre-treatment consisting of a water softener will be provided for the DI system fill and make-up water. Water for the system will be piped from the 4 utility stub provided at the entrance to the new facility. b. The DI plant will include as an option the pretreatment of carbon filters and RO skid. The base polishing system will include a polishing loop including mixed bed deionizers, UV lights, filters and DI storage tank. 3. Waste & Vent Piping a. Waste piping and venting for floor drains, lavatories, water closet and janitor sink located in the new space. Provide drains for the AHU's condensate drains. b. All new waste piping will terminate at a duplex sewage ejector. Pumped waste will be directed to the 4 sanitary waste utility stub provided at the entrance to the new facility. c. All new vent piping will be directed to the 2 vent utility stub provided at the entrance to the new facility. 4. Indirect Condensate Waste System a. An indirect waste system including condensate pumps carrying cooling coil condensate shall be provided to pump condensate from the air handling units which have cooling coils installed to the 4 mine waste water system utility stub provided at the entrance to the new facility. 5. Plumbing Piping Insulation a. Domestic cold water, hot water and recirculated hot water piping shall be insulated with fiberglass insulation with all service jacket and PVC fitting covers. 6. Plumbing Materials a. Domestic water and tempered water piping: Type L copper with 95/5 soldered joints. b. Sanitary waste and vent: Service weight cast iron with no-hub couplings above grade and hub-and-spigot joints below grade. c. Cooling coil condensate piping: DWV copper. d. High purity piping system will be (PVDF) polyvinylidene fluoride or high purity polypropylene (PP) with (BCF) bead and crevice free. E. FIRE PROTECTION SYSTEMS 1. Fire Protection System: a. A wet pipe sprinkler system shall be provided to protect all new Dunham Associates, Inc. Page 4/8
and remodeled spaces within the entire facility. New 4 zone piping will extend from the utility stub provided at the entrance to the new facility. The system characteristics remain unresolved. b. Up-right type fire sprinkler heads will be provided in all areas without ceilings. Semi-recessed Pendent type heads will be provided in all non-clean spaces with ceilings. Fully concealed, gasketed heads will be provided in all clean spaces with ceilings. c. Class 1 standpipes will be provided as per NFPA. F. CHILLED WATER COOLING SYSTEM 1. Chilled Water System: a. New chilled water supply and return piping will extend from the 4 utility stubs provided at the entrance to the new facility. The system characteristics require 150 GPM at 45 F EWT and 10 F delta. 2. Chilled Water Piping a. System piping shall be rolled grooved pipe with grooved couplings and fittings. b. Provide valving as required. 3. Chilled Water System Insulation a. Provide fiberglass insulation with thickness to meet applicable energy codes but a minimum thickness of 1". G. AIR HANDLING UNIT SYSTEMS 1. Cooling Air Handling Unit AHU-1 (Class 2000 Spaces) a. A 9200 CFM constant volume, variable temperature, air-handling unit will be provided to meet the air requirements for the class 2000 clean rooms and also to provide positive pressurization in the clean room spaces based on the classification of the space. The unit will be designed for indoor installation, being floor set. It will be fitted with MERV 8 pre-filter section, belt driven, smoke rated supply air fan and high efficiency motor, smoke rated dampers, a chilled water cooling coil w/stainless steel drain pan, electric reheat coil, 65 % efficient final filter section and a discharge plenum. The unit will be provided with insulated, double wall, water tight construction. Acceptable manufacturers are McQuay, Trane, Carrier and York. b. A 9200 CFM, smoke rated return/relief/exhaust fan will be provided (RF-1). Acceptable manufacturers are McQuay, Trane, Carrier and York. c. Variable speed drives will be provided for both AHU-1 and RF-1. d. The building automation system vendor will provide new unit controls. e. For fan sizing purposes, fan external static pressure shall be 3.5 of water column and total loaded filter pressure drop shall be 5.75 of water column. f. Chilled Water Cooling coil shall have an entering temperature of 67.5F db/53.8f wb and leaving temp of 54.5F db/48.9f wb. Dunham Associates, Inc. Page 5/8
g. Electric duct reheat coil heating coil shall be provided to heat the air from 55 to 70 deg F. using multi-stage electric resistance. It shall be located downstream of the cooling coils. h. Building Automation System Controls: Provide controls to modulate chilled water control valves as required to maintain discharge air temperature based on set point, which is adjusted, based on space relative humidity sensors. i. Ceiling mounted 99.9 % efficient HEPA filters will be provided in all Class 2000 spaces. 2. Cooling Air Handling Unit AHU-2 (Class 10,000 Spaces) a. A 27500 CFM constant volume, variable temperature, air-handling unit will be provided to meet the air requirements for the clean room and also to provide positive pressurization in the clean room spaces based on the classification of the space. The unit will be designed for indoor installation, being floor set. It will be fitted with 2-30% throw-away pre-filter section, belt driven smoke rated supply air fan and high efficiency motor, smoke rated dampers, 100% economizer section, chilled water cooling coil w/stainless steel drain pan, 99.9 % efficient HEPA final filter section and a discharge plenum. The unit will be provided with insulated, double wall, water tight construction. Acceptable manufacturers are McQuay, Trane, Carrier and York. b. A smoke rated 27500 CFM return/relief/exhaust fan will be provided (RF-2). Acceptable manufacturers are McQuay, Trane, Carrier and York. c. Variable speed drives will be provided for both AHU-2 and RF-2. d. The building automation system vendor will provide unit controls. e. For fan sizing purposes, fan external static pressure shall be 3.5 of water column and total loaded filter pressure drop shall be 5.75 of water column. f. Chilled Water Cooling coil cooling coil shall have an entering temperature of 71.4F db/57.5f wb and leaving temp of 55.0F db/51f wb. g. Electric duct reheat coils heating coils shall be provided to heat the air from 55 to 75 deg F. using multi-stage electric resistance. They shall be zoned and located out in the ductwork system. h. Building Automation System Controls: Provide controls to measure supply air flow, modulate the chilled water control valves, step the reheat coil to maintain discharge air temperature based on set point, which is adjusted, based on space relative humidity sensors. 3. Fan Coil Unit FC-1 and FC-2 a. The unit will be designed for indoor installation, hung from above. It will be fitted with 1-30% throw-away pre-filter section, belt driven supply air fan and high efficiency motor, chilled water cooling coil w/stainless steel drain pan and a discharge plenum. The unit will be provided with insulated, water tight construction. Acceptable manufacturers are McQuay, Trane and Carrier. Dunham Associates, Inc. Page 6/8
4. Outside/Relief/Smoke Exhaust Air Systems a. All new outside air ductwork will be drawn from the 30 Ø outside air utility duct stub provided at the entrance to the new facility. b. All new relief/smoke Exhaust air will be directed to the 30 Ø relief/smoke exhaust utility duct stub provided at the entrance to the new facility. 5. Exhaust Air Systems a. A 200 CFM constant volume, toilet exhaust fan will be provided to exhaust shower, toilet and janitor rooms. b. An 800 CFM lab hood exhaust fan will be provided. c. A 1000 CFM shop exhaust fan will be provided. d. A 500 CFM general exhaust serving the Physics & Chemistry area will be provided. e. All new lab exhaust will be directed to the 10 Ø exhaust utility duct stub provided at the entrance to the new facility. f. All new toilet exhaust will be directed to the 8 Ø toilet utility duct stub provided at the entrance to the new facility. g. All new general exhaust will be directed to the 16 Ø general utility duct stub provided at the entrance to the new facility. H. SMOKE CONTROL SYSTEM 1. Clean Room Unit AHU-1 (Class 2000) a. Smoke Control: During pressurization mode, the unit shall go to 100% economizer opening to full the outside air intake damper. The mixing damper shall close and the return/exhaust damper shall open fully. b. Smoke Control Dampers: various motorized smoke control dampers and two position VAV boxes within the supply and return ductwork shall modulate as required depending on if the mode is pressurization or exhaust. During exhaust mode, the exhaust air shall be diverted to the Class 2000 AHU return/exhaust ductwork. 2. Clean Room Unit AHU-2 (Class 10000) a. Smoke Control: During pressurization mode, the unit shall go to 100% economizer opening to full the outside air intake damper. The mixing damper shall close and the return/exhaust damper shall open fully. b. Smoke Control Dampers: various motorized smoke control dampers and two position VAV boxes within the supply and return ductwork shall modulate as required depending on if the mode is pressurization or exhaust. During exhaust mode, the exhaust air shall be diverted to the Class 10000 AHU return/exhaust ductwork. Dunham Associates, Inc. Page 7/8
I. SUPPLY/RETURN VENTILATION SYSTEM 1. Supply and return ductwork shall be galvanized sheet metal. Duct construction for recirculation units shall be designed per SMACNA standards for low-pressure duct systems and medium pressure duct systems for the make-up air-handling unit. Overall duct leakage in supply systems shall be design for less than 5% at 2 WC positive pressure. 2. Supply and return ductwork within the Torus shall be 316/304 stainless steel. Duct construction for recirculation units shall be designed per SMACNA standards for low-pressure duct systems and medium pressure duct systems for the make-up air-handling unit. Overall duct leakage in supply systems shall be design for less than 5% at 2 WC positive pressure. 3. Insulation on air supply and return duct shall be 2 thick, batt insulation. No insulation shall be required on exposed ductwork within the Torus. J. TEMPERATURE CONTROLS 1. Provide DDC control system for HVAC systems on this project. Controls shall be as indicated above and as follows: a. Hardware 1. DDC custom programmable controllers 2. DDC Temperature Sensors (plus or minus 1 degree F accuracy) 3. DDC Relative Humidity Sensors (plus or minus 1% accuracy) 4. Water Control Valves with electronic actuators (Belimo or equal) 5. Motorized dampers with electronic actuators (Belimo or equal). b. Acceptable Equipment Manufacturers: 1. Johnson Controls International. 2. Honeywell 3. Allerton 4. Automated Logic Dunham Associates, Inc. Page 8/8