Ormond Beach City Hall HVAC Assessment Report FOR THE CITY OF ORMOND BEACH 22 SOUTH BEACH STREET ORMOND BEACH, FL 32174 PERFORMED BY: great design|shapes the future wun ispolios, oe encopeeste inc. 352) 62De8H6 (382) 620-096 FINAL DRAFT: MARCH 18, 2013 "THC Rnginacring fr Architect Paget of 11 |. 874 Dixen Boulevard, Cooaa FL 32922-5809 ‘Ormond Beach City Hall HVAC AssessmentORMOND BEACH CITY HALL - HVAC ASSESSMENT REORT TABI ‘TENTS 1.0 Executive Summary 1.1 HVAC Assessment Process 1.2. Systems to be Assessed 1.3. General Building Description 1.4 Commissioning Findings A. General HVAC Notes 1. Air Handling Units 2. Chiller 3. Pumps: 4, Building Management System 1.8. Recommendations Appendix A, Pictures Appendix B, Phasing, Schedule and Costs TLC Baginecrng for Acivectre Page2 of 1 | 874 Dixon Boulevard, Coos FL 3 (Ormond Beach City Hall~ HVAC Assessment1.0 EXECUTIVE SUMMARY: The Ormond Beach City Hall is a two story, approximately 30,000 square foot building built in 1990. The majority of the City Hall's HVAC equipment was installed in 1990 making the equipment approximately 22 years old. The City Hall is cooled by a (1) 100 ton air cooled dual compressor chiller with (2) pumps providing chilled water to (3) air handling units (AHU’s). There are (3) split system air conditioning systems that serve the main entrance area. The building has (4) exhaust fans. The existing (3) AHU’s are in fair condition. With continued good maintenance, the existing AHU's have an expected 5-10 year of life expectancy. Replacing the AHU's as part of an overall project ‘would save construction costs and City costs associated with multiple construction projects. ‘The existing condensing units for the split systems have been replaced with new ones over the last 3-10 years. The systems use R-22 which has been discontinued. The split systems should be replaced with new modem refrigerant systems when each of the outdoor condensing units requires replacement in the future as part of a repair and replacement budget. ‘The building is served by one 100 ton dual compressor air cooled chiller. The chiller is 22 years old and has noticeable deterioration. The chiller has been repaired multiple times and will likely require repair of more components in the next 1-3 years. It is estimated that refurbishing the chiller would cost 70-80% of cost to replace with a new one. It is recommended that the chiller be scheduled to be replaced within the next year to avoid costs for temporary cooling or repair of a chiller beyond its life expectancy. Losing the chiller will leave the building without cooling. The chiller has 70 tons of connected cooling capacity. The 100 ton chiller is oversized for the current building's existing HVAC systems as it was sized for a future second floor expansion. A new chiller can be sized for 75 tons, saving the City the cost of the additional 25 tons of cooling. At an estimated installed cost of around $1000/ton, the reduced chiller size would save the City an ‘estimated $25,000, in addition to the energy savings that a new chiller would provide. ‘The pumps are old but appear to be in good operating condition. The frames are deteriorating and will eventually require replacement. There is full redundancy in the pumps (one full back-up). fone pump goes bad, a new pump can be purchased and replaced without completely losing the cooling system. The pumps can be replaced at the time of the next failure or be combined with the chiller replacement to minimize additional costs associated with multiple projects. The controls appear to be operating as scheduled with the chiller, pumps and AHU's starting on an occupied schedule. The control system components are obsolete. Replacing the controls with modem direct digital controls (DDC) will be cost effective in the long run and this should be considered within the next 5 years or if any of the system componenis start to fail. ‘See appendix B for anticipated one year and five year plans with associated costs. "TOC Engineering for Arcitere Page Sof || 874 Dizon Boulevard, Cocoa FL 32922 $609 ‘Ormond Beach City Hall~ HVAC Assessment1.1 HVAC ASSESSMENT PROCESS: ‘The HVAC assessment a systematic process that includes; documenting the existing HVAC equipment conditions, interviewing facility personnel associated with system ‘operations, reviewing the maintenance procedures, identifying equipments life expectancy and replacement versus keeping existing through maintenance and repair. Energy conservation measures will be identified when comparing replacement of existing with new. 1.2 SYSTEMS TO BE ASSESSED: A. The following systems were reviewed as part of the assessment process: List of Systems Assessed System Components Air Distribution System (3) Chilled Water AHU's, (3) Dx Split Systems (4) Exhaust Fans Ceniral Plant (2) Building CHW Pumps, (1)Air cooled chiller 1.3 GENERAL BUILDING DESCRIPTION: The Ormond Beach City Hall is @ two story, approximately 30,000 square foot building built in 1990. The building houses various city government support services. The majority of the City Hall's HVAC equipment was installed in 1990 making the equipment approximately 22 years old. The building's HVAC systems are controlled to a run during an occupied schedule ‘and shut off during an unoccupied schedule as follows: Mon.; Occupied from 4:00 am - 8:30 pm ‘Tues.-Fri; Ocoupied from 7:00 am — 8:30 pm ‘Sat-Sun; Occupied from 11:00 am-1:00 pm 1.4 COMMISSIONING FINDINGS: ‘A. HVAC General Notes: The City Hall is cooled by a (1) 100 ton air cooled dual compressor chiller with (2) pumps providing chilled water to (3) air handling units (AHU’s). There are (3) split system air conditioning systems thal serve the main entrance area. The building has (4) exhaust fans. Air handling unit's AHU-1 & AHU-2 serve the first floor and have a combined (29) zones with individual thermostat control. Each zone has variable air volume (VAV) damper boxes with electric heaters. The variable damper reduces the airflow to control the zone temperature. ‘The heater is activated if the zone temperatures drop 3°F below the thermostat setpoint while "TLC Bnginerng for Aciicure {874 Dixon Boulevard, Cocca FL 32922 5809 Pages of 11 (Ormond Beach City Hall-HIVAC AStessentthe VAV damper is at the minimum airflow position. AHU-3 serves the second floor and has 23 VAV zones with similar controls. The (3) split systems serve the main entrance area with the existing indoor unit's age estimated at 22 years. The existing condensing units for the split systems have been replaced with new ones over the last 3-10 years. The 100 ton chiller is oversized for the current building's existing HVAC systems, The original design called for a future expansion of the second floor. The chilled water system has future valves for an additional future AHU that was never installed. The connected building load associated with the (3) AHU's is approximately 70 tons. Any recommendations on replacing the existing chiller should also consider reducing the chiller size from 100 tons to 75 tons for both a cost and energy savings. Any future additions can be provided with a future chiller. The HVAC systems are controlled by the original 1990 control system. The controls use pneumatic valves with electronic transducers to convert pneumatic signals to electric for computer monitoring. The HVAC systems are being monitored off site by a dial up modem connection to the main controller. 1. Air Handling Unit Assessment Notes: The air handling units with regular maintenance can have a life expectancy of 30 years. The existing (3) AHU’s are in good condition with clean coils, minimal rust and litle vibration or noise observed from the moving components (see appendix A, pictures 1 and 2) With ‘continued good maintenance, the existing AHU's likely have an expected additional 5-10 year life expectancy. Replacing the air handling units as part of the chiller replacement project would save construction costs and City costs associated with multiple construction projects. The (3) split system indoor air conditioning systems are of a similar age as the (3) AHU's. ‘These systems use an outdated refrigerant (R-22). These systems should be replaced with new modem refrigerant systems when each of the outdoor condensing units requires replacement in the future (estimated between 5-10 years). The indoor unit's should be replaced at the same time as the outdoor units. The refrigerant lines should be replaced as well, 2. Chiller Assessment Notes: ‘The building is served by one 100 ton dual compressor air cooled chiller. The chiller is 22 years old. The frame has exceeded its life expectancy with noticeable rust on the frame and the condenser fans (Appendix A, pictures 3 and 4). The chiller condenser coils have Noticeable rust and are clogged beyond cleaning without possible damage to coils (Appendix A, picture 5). The controls are obsolete with the control parts very hard to obtain (see Appendix A, picture 6). The chiller has had several modifications over the years. A ‘condenser coil replacement was installed in 2002 (10 years old). One compressor was replaced in 1999 (13 years old) and one compressor was replaced in 2009 (3 years old). The chiller controls are the original 22 year old control board that is integral to the chiller. The TLC Enginorng for Arcitectare Page sof 1 | 874 Dizon Boutovard, Cosa FL 32922-5809 ‘Onmond Betch City Hall~ HVAC Assesmentchiller frame has noticeable rust and the coils appear to be dirty with noticeable corrosion {see appendix A picture). Coil replacements for exterior chillers located near a salt water ‘environment typically are typically required every 11-13 years. With the coil at 10 years old, they will require replacement within the next 1-3 years. The chiller controls appears to run ‘one compressor in lead all the time while the second compressor runs only when the building load requires additional cooling beyond the first stage. This explains the need to replace the lead compressor after the first 9 years with the second compressor lasting 19 years. The older 1999 lead compressor is stil running the majority of the time with the newer 2009 compressor used for the higher demand, hotter weather days. The 1899 compressor will likely require replacement in 1-3 years (similar to coils). Itis recommended that the chiller be replaced in the next 1-2 years. It is not recommended to replace coils, one compressor and maintain the control system for the existing chiller. It is estimated that re-furbishing the existing chiller would cost 70-80% of the cost of a new chiller. If the exiting chiller requires immediate replacement due to a failure; without a design, approved contractor and permits, temporary cooling would be required while a new chiller is obtained and installed. Lead times for obtaining a new chiller is estimated at 6-10 weeks. ‘Temporary cooling can cost an estimated $10,000-$15,000 per month. This further compels the City to proceed with plans to replace the existing chiller within the next year. Providing a reduced size higher efficiency chiller would reduce replacement cost and provide additional energy savings. Properly sized new chillers are much more efficient than 20+ year old chillers. 3, Pump Assessment: ‘There are two chilled water pumps that are located in the first floor mechanical room, The pumps are original existing frames (22 years old) and the frames have noticeable deterioration (see Appendix A, picture 7). The pumps were provided with new motors in 2002 (10 years old). Each pump is sized for full flow of the chiller with one pump as @ 100% redundant back-up. The pumps are controlled in a lead, lag sequence allowing for equal run time. Typically, well maintained pumps have a life expectancy of 20-25 years leaving the life expectancy for the existing pumps at approximately 3 years. The pumps should be considered for replacement in the next 1-3 years. 4, Building Management System Assessment: The controls are a combination of pneumatic VAV actuators, pneumatically controlled chilled water valves, pneumatic outside air dampers and electronic transducers (utilized to convert control signals from pneumatic to electronic) and electronic controllers with off-site computer monitoring of the control schedules and setpoints. The systems appear to be operating as. ‘scheduled with the chiller, pumps and AHU's starting according to an occupied schedule (see HVAC General Notes) and shutting off during unoccupied time periods. The controls are old (22 years) and replacement part costs are at a premium. "TLC Enginaring fr Architecture Page Sof 1 || 874 Dixon Boulverd, Cocoa FL 32922-5609 Ormond Beach City Hall HVAC AssessmentThe chiller controls are internal to the chiller and the chiller only receives a start and stop signal from the main controller. Replacement of the chiller will include replacement of chiller controls and reconnection of the existing start/stop control signal. Replacing the controls with modem direct digital controls (DDC) will be cost effective in the long run and this should be considered within the next 1-3 years. Proper control of equipment is the leading energy savings opportunities for building operations. 1.5 RECOMMENDATIONS: It is recommended that the chiller be scheduled to be replaced within the next year to avoid costs for temporary cooling or repair of a chiller beyond its life expectancy. The pumps should be considered for replacement in the next 1-3 years. It is recommended that the pumps be replaced with the chillers. Replacing the pumps as part of one construction project, will save in contractor mobilization costs and City costs associated with multiple projects. Replacing the controls with modern direct digital controls (DDC) will be cost effective in the long run and this should be considered within the next 5 years or if any of the system components start to fail. Replacing the air handling units as part of the chiller replacement project would save construction costs and City costs associated with multiple construction projects. See Appendix B for itemized replacement costs utilizing 2 plans; a one year plan with three options for replacing some or options presented, and a 5 year plan to replace each system independently over a five year period. Replacing all equipment on a one year plan (1 year ~ option 3) would provide an approximate $33,500 savings due to escalating equipment and labor costs over the 5 years. | Eee anton Page of $94 Dixon Boulevard, Cocca FL 32922-5809 ‘Onmond Beach City Hall HVAC AssesmentAppendix A, Picture 1 — AHU-3 ‘Tie Enginecrng fr Avitorre Page of11 | 874 Dixon Boulevard, Coe FL 32022-5509 ‘Orme Beach ity Hall HVAC Assessment"TLC Engineering for Architetare {874 Dison Boulevard, Cocos FL 32922-5809 Appendix A, Picture 2 — AHU-1 ¥ Page 011 ‘Ormand Beach City all HVAC AssesmentAppendix A, Picture 4 — Chiller d45453%3 Appendix A, Picture 5 — Chiller Coil RE a "TIC Eaginesing or Arshitoaare Page 10 of | 374 Dixon Boulevard, Cocom PL 32922-5609 ‘Onmond Beach City Hall HVAC AssesmentAppendix A, Picture 6 — Chiller Control Panel "TLC Enginoring for Arcivonure Page of) [84 Dixon Boulevard, Cocoa FL 32822-5809 ‘Ormond Beach City Hall HVAC AssestentAppendix B PHASING, SCHEDULE & COSTS FOR ONE YEAR PLAN PHASE ‘OPTION 4: REPLACE CHILLER DESIGN BID CONSTRUCTION START CONSTRUCTION COMPLETE 4/13-10/13_ |ENGINEER DESIGN AND C/A/ COSTS [OPTION 2: REPLACE CHILLER, PUMPS & CONTROLS ays DESIGN 53 eID 6/13 CONSTRUCTION START 9/13 CONSTRUCTION COMPLETE 4/13-10/13 _ | ENGINEER DESIGN AND C/A/ COSTS JOPTION 3: REPLACE CHILLER, PUMPS, CONTROLS & AHU'S 4/13 DESIGN 5/13 BID 6/13 CONSTRUCTION START 10/13 CONSTRUCTION COMPLETE 4/13-10/13 ENGINEER DESIGN AND C/A/ COSTS TOTAL COST - OPTION 3Appendix B PHASING, SCHEDULE & COSTS FOR FIVE YEAR PLAN. PHASE YEAR 1: REPLACE CHILLER DESIGN BID CONSTRUCTION START CONSTRUCTION COMPLETE 4/13-10/13 | ENGINEER DESIGN AND C/A/ COSTS |VEAR 3: REPLACE PUMPS & CONTROLS ans DESIGN 5/15 BID 61s CONSTRUCTION START 9s CONSTRUCTION COMPLETE 4/15-10/15 _|ENGINEER DESIGN AND C/A/ COSTS: YEAR 5: REPLACE AHU'S 4/37 DESIGN 5/17 BID 6/17 CONSTRUCTION START 10/17 _| CONSTRUCTION COMPLETE 4/17-10/17 _|ENGINEER DESIGN AND C/A/ COSTS ‘AL - ALL 3 PROJECTS OVER 5 YEARS