Ross Parkman PE Ryan Wester PE Central Chiller Plant Experience Big Ten and Friends Mechanical and Energy Engineering Conference October 1, 2013

2 Discussion Topics Planning Design Project Delivery and Construction Commissioning and Startup Operations Q&A Facilities Operation and Development

3 Significant Planning Milestones Feasibility Study Med Center Chiller PlantJune 2004 Campus Infrastructure Master PlanMarch 2006 Preliminary Design and Cost EstimateSept 2006 Additional Studies and Value Engineering Redesign option for “Building Loop” Planning/design New Bed Tower and Existing Hospital HVAC Upgrades Feasibility Study/Life Cycle Cost for “Building Loop” vs. Central Plant Plant Site Studies (W of Cannon / 10 th Ave, W of Cannon / E of Cannon) A/E and Construction Manager ContractsAug2009 Program of Requirements Oct2009 Estimate of Probable CostNov2009 Facilities Operation and Development

4 Key Project Dates Chiller Order 2500 tons)June 2010 Construction Start January 2011 Initial Equipment TestingMay 2012 “Construction” Chilled WaterAugust 2012 “Reliable” Chilled WaterOctober 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 Facilities Operation and Development

5 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 Facilities Operation and Development

6 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 Facilities Operation and Development

7 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 pipe 12” inch seamless steam pipe 6” 316L stainless steel condensate pipe Valve vaults and provision for future building connections Chilled Water Distribution Direct buried HDPE Transition 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 Facilities Operation and Development

8 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 Facilities Operation and Development

9 3D BIM Construction Model of #1 Chiller (Navisworks )

10 Installation of chillers on second floor of the plant

11 Inspections Construction Structural steel and concrete UT weld examinations: steam, chiller water and condensate piping Hydrostatic tests A/E as Contract Administration Construction Manager Final Inspections ODIC <=480 volt electrical Building systems Life Safety OSU Utilities (as AHJ) 575V and higher electrical Instrumentation and control wiring Process piping and equipment Facilities Operation and Development

12 Equipment Readiness Mechanical Vendor/Contractor startup support Pipe 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 support Phase checks Relay and wiring checkout Controls Field instrument calibration and verification Point to point zero and span check 134 field devices, one time, complete through to the graphical interface Verified wiring, communication and graphical displays for 3500 total points. Facilities Operation and Development

13 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, Chillers Tested chillers with “warm” loop water prior to building conversions Go live Building chillers kept as backup for two weeks Midnight 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 Generators Tested load share with utility Controlled load assumption Full Black Start Test Third building conversion (10/16/12) Facilities Operation and Development

14 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 Facilities Operation and Development

15 Facilities Operation and Development

16 Facilities Operation and Development Questions?

17 Thanks to the Project Team! Facilities Operation and Development