1. KINGDOM OF SAUDI ARABIA
ROYAL COMMISSION FOR JUBAIL & YANBU
ROYAL COMMISSION IN JUBAIL
CONTRACT NO : 641-C46
REHABILITATION OF RC HOSPITAL
SITE INFRASTRUCTURE
GMTA PRESENTATION
AUGUST 2014
4. HIGHWAY4HIGHWAY4
EMERGENCY
ENTRANCE
OVERALL SITE LAYOUT
THE SCOPE OF WORK INCLUDE:
STUDY AND INSPECTION OF EXISTING SITE UTILITIES
RENEWAL / REHABILITATION OF EXISTING UTILITY
SYSTEMS
BRING EXISTING FACILITIES TO CURRENT CODE
REQUIREMENTS
REPLACEMENT / REHABILITATION OF CONTROL
SYSTEMS ASSOCIATED WITH MECHANICAL SYSTEMS
CHANGING MEDIUM VOLTAGE TO LOW VOLTAGE FOR
THE CHILLERS
POTENTIAL REHABILITATION INCLUDES:
CHILLED WATER SYSTEM
STEAM SUPPLY SYSTEM
HOT AND COLD WATER SYSTEMS
DISTRIBUTION PIPING SYSTEMS
EMERGENCY POWER
MEDICAL GAS SYSTEMS
ELECTRICAL SUPPLY
TELECOMMUNICATION SYSTEM
FIRE HYDRANTS
5. POTENTIAL REHABILITATION
CHILLED WATER SYSTEM
STEAM SUPPLY SYSTEM
HOT AND COLD WATER SYSTEMS
DISTRIBUTION PIPING SYSTEMS
EMERGENCY POWER
MEDICAL GAS SYSTEMS
ELECTRICAL SUPPLY
THE SCOPE OF REHABILITATION INCLUDES:
6.
7. CONDITION SURVEY-CHILLER COMPOUND
CHILLER COMPOUND
LAYOUT
KEY PLAN
MAIN PIPES GOES THRU
TUNNEL THEN UNDER RAMP
MAIN PIPE HEADER WITH
SUPPORTS
NE.CH-7
PROPOSED
REPLACE CHILLERS:
OPTION 1 – 8 CHILLERS FOR N+2 VERSUS
OPTION 2 – 11 CHILLERS FOR 100% REDUNDANCY
PIPING HEADERS REPLACED BACK TO PUMP HOUSE
MOVE NEW CHILLERS TO MEET CHILLER
MANUFACTURER CLEARANCE RECOMMENDATION
ADD SUPERVISORY CONTROLS AND METERING
OPTION-2
EXISTING CONDITION
FOURTEEN (14) TRANE AIR-COOLED CHILLERS
ELEVEN (11) TRANE AIR-COOLED CHILLERS INSTALLED IN 1980s
286 TON CENTRIFUGAL CHILLERS (OBSOLETE)
4160V MACHINES
FIVE (5) ARE IN WORKING CONDITION, REMAINING CHILLERS ARE OUT OF
SERVICE
THREE (3) TRANE AIR-COOLED CHILLERS INSTALLED IN 2008
400 TON SCREW CHILLERS
480V MACHINES
THE CHILLED WATER PIPING FROM CHILLER COMPOUND TO CHILLED WATER PUMP ROOM DOES NOT
SHOW VISUAL SIGNS OF LEAKAGE EXCEPT AT SPECIFIC TIE IN POINTS TO THE CHILLERS.
8. CONDITION SURVEY-CHILLER COMPOUND
CHILLER COMPOUND
LAYOUT
KEY PLAN
MAIN PIPES GOES THRU
TUNNEL THEN UNDER RAMP
THREE SCREW TYPE CHILLERS-2010
400 TON
480V MACHINES
EXISTING CONDITION:
ELEVEN CENTRIFUGAL CHILLERS(OBSELETE)-1986
300 TON
4160V MACHINES
FIVE (5) ARE IN WORKING CONDITION, REMAINING
CHILLERS ARE OUT OF SERVICE
MAIN PIPE HEADER WITH
SUPPORTS
NE.CH-7
9. CONDITION SURVEY-CHILLER COMPOUND
CHILLER COMPOUND
LAYOUT
KEY PLAN
MAIN PIPES GOES THRU
TUNNEL THEN UNDER RAMP
MAIN PIPE HEADER WITH
SUPPORTS
NE.CH-7
RECOMMENDATIONS:
REPLACE CHILLERS:
OPTION 1 – 8 CHILLERS FOR N+2 VERSUS
OPTION 2 – 11 CHILLERS FOR 100% REDUNDANCY
PIPING HEADERS REPLACED BACK TO PUMP HOUSE
ADD SUPERVISORY CONTROLS AND METERING
OPTION-2
10. CONDITION SURVEY-CHILLED WATER PUMP ROOM
CHILLED WATER PUMP ROOM
LAYOUT
KEY PLAN
NE.CHWP-1&2
UTILITY TUNNEL ACCESS
PROPOSED
REPLACE 3 CHILLED WATER PUMPS
REPLACE PIPING WHEN PUMPS ARE REPLACED
EXPAND OPD PUMP ROOM TO PROVIDE ACCESS TO PUMPS
ADD SUPERVISORY CONTROLS AND METERING
NEW OPD PUMP ROOM WITH 2
NE.CHW.PUMPS
EXISTING CONDITION
SIX (6) CHILLED WATER PUMPS SERVING ESSENTIAL AND NON-ESSENTIAL
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING OPD CHILLED WATER CIRCUIT
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING NON-ESSENTIAL CHILLED WATER CIRCUIT
ONE PUMP IS NOT IN SERVICE
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING ESSENTIAL CHILLED WATER CIRCUIT
THE CHILLED WATER PIPING HEADERS SHOW MINOR SIGNS OF LEAKAGE
EXPANSION OF OPD
PUMP ROOM
11. CONDITION SURVEY-CHILLED WATER PUMP ROOM
CHILLED WATER PUMP ROOM
LAYOUT
KEY PLAN
NE.CHWP-1&2
UTILITY TUNNEL ACCESS
NEW OPD PUMP ROOM WITH 2
NE.CHW.PUMPS
EXISTING CONDITION:
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING OPD CHILLED WATER CIRCUIT
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING NON-ESSENTIAL CHILLED WATER CIRCUIT
ONE PUMP IS NOT IN SERVICE
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING ESSENTIAL CHILLED WATER CIRCUIT
12. CONDITION SURVEY-CHILLED WATER PUMP ROOM
CHILLED WATER PUMP ROOM
LAYOUT
KEY PLAN
NE.CHWP-1&2
UTILITY TUNNEL ACCESS
RECOMMENDATIONS:
REPLACE 3 CHILLED WATER PUMPS
REPLACE PIPING WHEN PUMPS ARE REPLACED
EXPAND OPD PUMP ROOM TO PROVIDE ACCESS TO
PUMPS
ADD SUPERVISORY CONTROLS AND METERING
NEW OPD PUMP ROOM WITH 2
NE.CHW.PUMPS
13. S.NO. ROOM NAME CODE REQUIREMENT
COMPLIANCE WITH
CODE
RECOMMENDATION
1 Chiller Compound
Mechanical utilities shall have
proper access, clearance and
location and must be as per RC
engineering requirements.
Refer to RC Engineering
Manual, Chapter 6 section
6.16(C, D, E).
Yes
Install new chillers per
manufacturer required
clearance
2
Chilled Water Pump
Room (Old)
Yes
Piping replacement and
relocation will improve tunnel
access.
3
Chilled Water Pump
Room (New)
No
The new chilled water pump
room is recommended for
expansion so as to gain space
for both the existing pumps.
CODE COMPLIANCE SUMMARY
14. CONDITION SURVEY-POWER
PLANT
KEY PLAN
POWER PLANT LAYOUT
CALORIFIERS
STEAM HEADER
BOILER PIPES AND FLUE STACK
PROPOSED
REPLACE BOILER 1, BLOW DOWN TANK ,
2 CALORIFIERS
RENOVATE ONE BOILER
REPLACE PIPING IN PLANT
ADD SUPERVISORY CONTROLS AND METERING
EXISTING CONDITION
STEAM PRODUCED WITH 2 FIRE-TUBE BOILERS
COCHRAN 1254 kW FIRE-TUBE BOILERS
INSTALLED IN 2001 AND 2010
REPORTED TUBE LEAKS, ISSUES WITH CHEMICAL TREATMENT
MANUAL BLOWDOWN VALVE
CONDENSATE RETURN TANK AND DEAREATOR REPLACED IN 2010
BLOW DOWN TANK INSTALLED IN 1980s
FOUR (4) FUEL OIL PUMPS INSTALLED IN 1980s
WATER TREATMENT REPLACED IN 2010
HOT WATER PRODUCED WITH 6 CALORIFIERS
FOUR (4) SERVE DOMESTIC HW (N+2)
TWO (2) INSTALLED IN 2010
TWO CURRENTLY NOT IN SERVICE
TWO (2) SERVE LAUNDRY, INSTALLED IN 2010
STEAM PIPES AND VALVES SHOW VISIBLE SIGNS OF LEAKAGE AND TEMPORARY REPAIRS
15. CONDITION SURVEY-POWER
PLANT
KEY PLAN
POWER PLANT LAYOUT
2.CALORIFIERS
1.STEAM HEADER
BOILER PIPES AND FLUE STACK
TWO FIRE TUBE STEAM BOILERS
BOILER-1 INSTALLED IN 2012
BOILER-2 INSTALLED IN 2001
REPORTED TUBE LEAKS, ISSUES WITH CHEMICAL TREATMENT
SYSTEM
SIX CALORIFIERS, FOUR NEW AND TWO OLD(NOT IN SERVICE)
NEW CONDENSATE RECEIVER TANK AND DEAREATOR
STEAM PIPING AND VALVES SHOW VISIBLE SIGNS OF LEAKAGE
16. CONDITION SURVEY-POWER
PLANT
KEY PLAN
POWER PLANT LAYOUT
2.CALORIFIERS
1.STEAM HEADER
BOILER PIPES AND FLUE STACK
RECOMMENDATIONS:
REPLACE BOILER-2, BLOW DOWN TANK,
2 CALORIFIERS
RENOVATE BOILER-1
REPLACE PIPING IN PLANT
ADD SUPERVISORY CONTROLS AND METERING
17. S.NO. ROOM NAME CODE REQUIREMENT
COMPLIANCE WITH
CODE
RECOMMENDATION
4 Power Plant
Mechanical utilities shall have
proper access, clearance and
location and must be as per RC
engineering requirements.
Refer to RC Engineering
Manual, Chapter 6 section
6.16(C, D, E).
Yes
Piping replacements will result
in improved tunnel access.
5 Utility Tunnel No
The work inside the tunnel must
be as per approved mechanical
option.
6
Water Reservoir and
Pump room
Yes
Water reservoir and pump room
are currently being upgraded.
Proper ventilation must be
provided as per code
requirements.
CODE COMPLAINCE SUMMARY
18. CONDITION SURVEY-FUEL STORAGE
TANKS
REPLACE FILL STATION
PROVIDE CONTAINMENT PAD AT FILL STATION
ADD SUPERVISORY CONTROLS AND METERING
FUEL STORAGE TANK
LAYOUT
2 FUEL
TANKS
FILL
STATION
FUEL PIPING IN
TRENCH
19. CONDITION SURVEY-MEDICAL GAS
SYSTEM
OXYGEN STORAGE TANK
LAYOUT
REPLACE 1 COMPLETE TANK ASSEMBLY
REPLACE PIPING TO MANIFOLD ROOM
ADD SUPERVISORY CONTROLS AND METERING
ADD BOLLARDS AROUND OXYGEN STORAGE TANK AREA
2 OXYGEN
TANKS
OLD OXYGEN
TANK
21. LIFE SAFETY REQUIREMENTS
UTILITY TUNNEL SATISFIES SAFETY RECOMMENDATIONS
NFPA 101 40.2.1.2 – NORMALLY
UNOCCUPIED UTILITY CHASES THAT ARE
SECURED FROM UNAUTHORIZED ACCESS
AND ARE USED EXCLUSIVELY FOR
ROUTING OF ELECTRICAL, MECHANICAL,
OR PLUMBING EQUIPMENT SHALL NOT BE
REQUIRED TO COMPLY WITH THE
PROVISIONS OF CHAPTER 7 (MEANS OF
EGRESS)
STANDARD INDUSTRY PRACTICE
RECOMMENDS MEANS OF EGRESS EVERY
100 METERS (TUNNEL MAXIMUM 80 M)
OSHA 1926.1023 LADDERS (TUNNEL OK)
ACCESS TO
TUNNEL FROM
POWER PLANT
ROOM
ACCESS TO
TUNNEL FROM
CHILLED
WATER PUMP
ROOM
POWER
PLANT
CHILLED
WATER PUMP
ROOM
UTILITY
TUNNEL
PIPES RISING IN
MECHANICAL
ROOM FROM
TUNNEL
22. Switchgear & chilled water pump house building
Current MV Normal Switchgear
Proposed location for LV
Switchgear
KEY PLAN
EXISTING CONDITION:
THE MV-SWITCHGEAR AND CHILLER CONTROL PANELS ARE
OLD AND OBSOLETE.
Existing MV Switchgear Room
Current MV Essential Switchgear
CONDITION SURVEY-ELECTRICAL SYSTEM
23. Switchgear & chilled water pump house building
Existing MV Switchgear Room
KEY PLAN
Current MV Normal Switchgear
Proposed location for LV
Switchgear
Current MV Essential Switchgear
RECOMMENDATION:
THE MEDIUM VOLTAGE SWITCHGEAR PANEL, CHILLER CONTROL
PANELS, POWER AND LIGHTING PANELS, SHALL BE REPLACED
DUE TO THE CHANGE IN THE NOMINAL VOLTAGE.
SWITCHING FROM MEDIUM VOLTAGE TO LOW VOLTAGE
REQUIRES ADDITIONAL CHANGES IN POWER.
ADD NEW GENERATOR TO FULFILL THE INCREASED LOAD
REQUIREMENTS AND SEPARATING CHILLER BACKUP POWER.
CONDITION SURVEY-ELECTRICAL SYSTEM
25. Existing service Tunnel (yellow) shown on Pile layout plan
Tunnel Section Inside
Building Edge
Tunnel Section Outside
Building Edge
A A
Section A-A
B B
Section B-B
Existing Tunnel
Outside Building
Edge
Outside Building
Edge
Concrete
Piles
26.
27. 26
EXISTING PIPING NETWORK
NE CHW
E CHW
STM & COND
NECHW
ECHW
STM&COND
PUMP
HOUSE
NE CHWS
E CHWS
NE CHWR
E CHWR
POWER
PLANT
HOSPITAL
SHAFT
MECHANICAL
ROOM
CW
HW
CW
HW
CW
HW
A
C
B
D
HOSPITAL
SHAFT
POWER
PLANT
MECHANICAL
ROOM
PUMP
HOUSE
CHILLER
YARD
CHILLER
YARD
MU
E CHW
E CHWR
NE CHWR
STM & COND
28. APPROACH: CREATE ROOM IN TUNNEL BY
RELOCATING COLD WATER, HOT WATER AND
NON-ESSENTIAL CHILLED WATER PIPING
REPLACE REMAINING PIPING IN PHASES,
CREATING DUPLICATE PATHWAYS, THEN
DEMOLISH EXISTING PIPE
MAINTENANCE SPACE CREATED FOR STEAM
PIPING
OPTION 1 – TUNNEL
OPTIMIZATION
Option 1
EXISTING TUNNEL
29. 28
OPTION 1 – Phasing
A
C
B
D
HOSPITAL
SHAFT
POWER
PLANT
MECHANICAL
ROOM
PUMP
HOUSE
CHILLER
YARD
NEW BOX TRENCH:
6 COLD AND HOT
WATER PIPES
NEW BOX TRENCH:
2 CHILLED WATER
PIPES
EXISTING TUNNEL:
4 TO 6 CHILLED
WATER AND STEAM
PIPES
Step 1 – create dual path for cold and hot water(Box trench)
Step 2 – connect new piping and demo old
Step 3 – create dual path for chilled water(Box trench)
Step 4 – connect new piping and demo old
Step 5 – create dual path for STEAM(Tunnel A,B,C&D)
Step 6 – connect new piping and demo old
Step 7 – create dual path for E CHW (Tunnel A)
Step 8 – connect new piping and demo old
Step 9 – create dual path for NE CHW (Tunnels D&C). Steps 9 & 10 must be
completed one pipe at a time (supply, then return)
Step 10 – connect new piping and demo old
Step 11 – create dual path for E CHW (Tunnels B, C, D). Steps 11 & 12 must be
completed one pipe at a time (supply, then return)
Step 12 – connect new piping and demo old
30. 29
OPTION 1 – STEP 12 Connect new pipe
& demo
HOSPITAL
SHAFT
POWER
PLANT
MECHANICAL
ROOM
PUMP
HOUSE
CHILLER
YARD
E CHW
ECHW
PUMP
HOUSE
POWER
PLANT
HOSPITAL
SHAFT
MECHANICAL
ROOM
CHILLER
YARD
CW
HW
NECHW
STM & COND
STM&COND
MU
STM & COND
E CHWE CHWR
E CHWS
E CHWR
NE CHW
NE CHWR
NE CHWS
NEW BOX TRENCH:
6 COLD AND HOT
WATER PIPES
NEW BOX TRENCH:
2 CHILLED WATER
PIPES
EXISTING TUNNEL:
4 TO 6 CHILLED
WATER AND STEAM
PIPES
31. ADVANTAGES:
Results in adequate maintenance space for steam and
condensate piping
DISADVANTAGES:
Multiple times when contractor will be coordinating temporary
interruptions for switching utilities with phased approach
Difficult working conditions will increase time for demolition
and replacement
Additional piping routed through mechanical room
Contractor will be working in tunnel with live steam leak
OPTION 1 – TUNNEL OPTIMIZATION
SUMMARY
32. OPTION 2A – OVERHEAD
BRIDGE
CREATE DUAL PATHWAY FROM
PUMP HOUSE AND POWER
PLANT TO MECHANICAL
ROOM AND HOSPITAL SHAFT
REMOVE EXISTING PIPING IN
TUNNEL LEAVING ELECTRICAL
TRAY OR ABANDON
COMPLETELY EXISTING
TUNNEL MOVING ELECTRICAL
TRAY TO NEW BRIDGE.
PROPOSED WALK OVER
UTILITY BRIDGE
POWER PLANT
CHILLER
COMPOUND
RC HOSPITAL
LEVEL-2 ROOF
RC HOSPITAL
LEVEL-5
ROOF
CHILLED WATER PUMP ROOM &
SWITCH GEAR ROOM
PROPOSED SHAFT IN
MECHANICAL ROOM
PROPOSED
HOSPITAL SHAFT
33. OPTION 2A – OVERHEAD
BRIDGE
SECTION A SHOWING PIPE ARRANGEMENT ON
THE BRIDGE
1500 mm
A
34. OPTION 2A – OVERHEAD BRIDGE
SUMMARY
ADVANTAGES:
Overhead bridge will be constructed before demolishing any of
the existing pipes
Mechanical system will remain in service until new utilities are
replaced
Results in adequate space for ease of maintenance
DISADVANTAGES:
Some architectural modifications are required within
hospital building to accommodate new mechanical shafts
35. OPTION 2B – TUNNEL & OVERHEAD
BRIDGE
CREATE DUAL PATHWAY FROM
PUMP HOUSE AND POWER
PLANT TO MECHANICAL ROOM
AND HOSPITAL SHAFT
REMOVE EXISTING PIPING IN
TUNNEL LEAVING ELECTRICAL
TRAY OR ABANDON THE
EXISTING TUNNEL COMPLETELY
MOVING ELECTRICAL TRAY TO
NEW TUNNEL.
PROPOSED
TUNNEL-2PROPOSED
TUNNEL-1
RC HOSPITAL
LEVEL-2 ROOF
RC HOSPITAL
LEVEL-5
ROOF
PROPOSED SHAFT IN
MECHANICAL ROOM
PROPOSED
HOSPITAL SHAFT
POWER PLANT
CHILLED WATER PUMP ROOM &
SWITCH GEAR ROOM
CHILLER
COMPOUND
36. OPTION 2B – TUNNEL AND OVERHEAD
BRIDGE
SECTION A SHOWING PIPE ARRANGEMENT IN THE
NEW TUNNEL
1500 mm
A
37. ADVANTAGES:
Tunnel and overhead bridge will be constructed before
demolishing any of the existing pipes
Mechanical system will remain in service until new utilities are
replaced
Results in adequate space for ease of maintenance
DISADVANTAGES:
Higher initial cost
Some architectural modifications are required within hospital
building to accommodate new mechanical shaft
Requires construction above hospital ceiling space for cold and hot
water piping
OPTION 2B – TUNNEL AND OVERHEAD
BRIDGE
38. CREATE ROOM IN TUNNEL BY RELOCATING COLD
WATER, HOT WATER AND NON-ESSENTIAL CHILLED
WATER PIPING
REPLACE REMAINING PIPING IN PHASES,
COMBINING NON-ESSENTIAL AND ESSENTIAL
PIPING TO CREATE MORE AVAILABLE SPACE
ADD NECESSARY VALVING AND CONTROLS TO
ISOLATE ESSENTIAL PIPING
OPTION 3 – COMBINE NE & E CHW
PIPING
EXISTING TUNNEL
39. ADVANTAGES:
Results in fewer pipes to maintain/creates additional space
DISADVANTAGES:
Multiple switch over required with phased approach
Temporary piping will run through hallway during (Section D)
demolition and replacement
Difficult working conditions will increase time for demolition
and replacement
Requires use of ceiling space for cold and hot water piping
Contractor working in tunnel with live steam
Requires window welds to install pipe
Due to risk associated with constructability of Option 3, we do
not recommend moving forward with Option 3
OPTION 3 – COMBINE NE & E CHW PIPING
SUMMARY
40. EQUIPMENT
NO INTERRUPTIONS OF SERVICE TO HOSPITAL(ALL EQUIPMENTS
WITH REDUNDANCY)
SEQUENCING AND SERVICE INTERRUPTIONS
41. THE EXISTING REDUNDANCY OF THE SYSTEMS WILL ALLOW A PHASED
REPLACEMENT OF EQUIPMENT WITHOUT INTERUPTION TO THE
HOSPITAL OPERATIONS
CHILLERS
CHILLED WATER PUMPS
BOILERS
CALORIFIERS
OXYGEN TANK SYSTEM
OPTIONS 1 OR 2 WILL ALLOW A REDUNDANT STEAM, CONDENSATE,
CHILLED WATER, AND HOT & COLD WATER PATHWAY TO BE CREATED
BEFORE THE EXISTING PIPING SYSTEMS ARE REMOVED
PROVIDE NEW GENERATOR BEFORE DISCONNECTING POWER TO
CHILLERS
SEQUENCING AND SERVICE INTERRUPTIONS
42. GIVEN THE RISKS ASSOCIATED WITH THE CONSTRUCTABILITY OF
OPTIONS 1 & 3, THE RISKS OF HAVING CONTRACTORS WORKING NEAR
LIVE STEAM LEAKS, AND THE RISKS TO HOSPITAL OPERATIONS BY
CONDUCTING MULTIPLE SWITCH OVERS (FROM OLD TO NEW PIPING),
WE RECOMMEND MOVING FORWARD WITH OPTION 2.
THE DIFFERENCE IN COST BETWEEN 2A AND 2B IS WITHIN THE
UNCERTAINTY OF THE COST ESTIMATES.
OPTION 2A IS EASIER TO ROUTE PIPE TO THE EXISTING CONNECTION
LOCATIONS AND WILL BE MORE MAINTAINABLE DUE TO BETTER
ACCESS TO PIPES.
THE THREE OPTIONS HAVE BEEN PRESENTED TO END USER DURING
WORKSHOPS, AND THEY FAVORED OPTION 2A – OVERHEAD
DISTRIBUTION.
PIPING DISTRIBUTION RECOMMENDATION
43. RECOMMEND MOVING FORWARD WITH:
CHILLED WATER SYSTEM
REPLACING 11 CHILLERS
REPLACING 3 CHILLED WATER PUMPS
REPLACING ALL CHILLED WATER PIPING
HOT WATER SYSTEM
REPLACING BOILER 1, RENOVATING BOILER 2
REPLACING IDENTIFIED ANCILLARY EQUIPMENT
REPLACING TWO CALORIFIERS
FUEL OIL SYSTEM
REPLACE FILL STATION
ADD CONTAINMENT PAD
RECOMMENDATION
44. RECOMMEND MOVING FORWARD WITH (CONTINUED):
MEDICAL GAS SYSTEM
REPLACE ONE OXYGEN TANK SYSTEM
REPLACE PIPING FROM TANKS TO MANIFOLD
ADD ISOLATION BOLLARDS
DISTRIBUTION PIPING
REPLACE ALL PIPING AND FITTINGS
ROUTE PIPE IN NEW OVERHEAD BRIDGE (OPTION 2A)
RECOMMENDATION
45. RECOMMEND MOVING FORWARD WITH (CONTINUED):
ELECTRICAL SYSTEM
CONSTRUCT NEW LV - SWITCHGEAR ROOM
REPLACE SWITCHGEAR PANEL, CHILLER CONTROL PANELS
CWSA, CWSG AND CWH1, POWER AND LIGHTING PANELS
CWA, CWB AND CWB
REPLACE MOTOR CONTROL CENTRES
INSTALL NEW GENERATOR 1750 KVA
UPGRADE FIRE ALARM SYSTEM FOR SWITCHGEAR AND
CHILLED WATER PUMP HOUSE.
RECOMMENDATION
46. SUMMARY
OPTION 1 OPTION 2A OPTION 2B OPTION 3
TUNNEL
OPTIMIZATION
OVERHEAD BRIDGE TUNNEL AND
OVERHEAD
COMBINE NE & E
CHW
COST 59,111,000 55,658,000 57,640,000
NOT
RECOMMENDED
PHASING Complex phasing Simple phasing Simple phasing
COMPLEXITY
Difficult working
conditions and
limited access
Not complex and
easy installation
Not complex and
easy installation
Editor's Notes
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES
EQUIPMENT:
FOURTEEN (14) TRANE AIR-COOLED CHILLERS
ELEVEN (11) TRANE AIR-COOLED CHILLERS INSTALLED IN 1990s
300 TON CENTRIFUGAL CHILLERS. PAST THEIR USEFUL LIFE & OBSOLETE. CAN NO LONGER GET PARTS FOR MACHINES
4160V MACHINES (NEW SERVICE WILL BE 480V)
FIVE (5) ARE IN WORKING CONDITION, REMAINING CHILLERS ARE OUT OF SERVICE
RECOMMEND REPLACING 4 ESSENTIAL CHILLERS WITH 300 TON CHILLERS, AND 4 OF 7 NON-ESSENTIAL MACHINES WITH 400 TON CHILLERS
THREE (3) TRANE AIR-COOLED CHILLERS INSTALLED IN 2010
400 TON SCREW CHILLERS
480V MACHINES
THE CHILLED WATER PIPING FROM CHILLER COMPOUND TO CHILLED WATER PUMP ROOM DOES NOT SHOW VISUAL SIGNS OF LEAKAGE EXCEPT AT SPECIFIC CONNECTIONS TO THE CHILLERS. GIVEN THE AGE OF THE PIPING NETWORK AND PAST CORROSION ISSUES DUE TO WATER QUALITY, QUOTES FOR NON-DESTRUCTIVE THICKNESS TESTING WERE OBTAINED AND ARE COSTLY ENOUGH TO RECOMMEND REPLACING PIPE INSTEAD OF HIRING TESTING SERVICES.
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES
EQUIPMENT:
FOURTEEN (14) TRANE AIR-COOLED CHILLERS
ELEVEN (11) TRANE AIR-COOLED CHILLERS INSTALLED IN 1990s
300 TON CENTRIFUGAL CHILLERS. PAST THEIR USEFUL LIFE & OBSOLETE. CAN NO LONGER GET PARTS FOR MACHINES
4160V MACHINES (NEW SERVICE WILL BE 480V)
FIVE (5) ARE IN WORKING CONDITION, REMAINING CHILLERS ARE OUT OF SERVICE
RECOMMEND REPLACING 4 ESSENTIAL CHILLERS WITH 300 TON CHILLERS, AND 4 OF 7 NON-ESSENTIAL MACHINES WITH 400 TON CHILLERS
THREE (3) TRANE AIR-COOLED CHILLERS INSTALLED IN 2010
400 TON SCREW CHILLERS
480V MACHINES
THE CHILLED WATER PIPING FROM CHILLER COMPOUND TO CHILLED WATER PUMP ROOM DOES NOT SHOW VISUAL SIGNS OF LEAKAGE EXCEPT AT SPECIFIC CONNECTIONS TO THE CHILLERS. GIVEN THE AGE OF THE PIPING NETWORK AND PAST CORROSION ISSUES DUE TO WATER QUALITY, QUOTES FOR NON-DESTRUCTIVE THICKNESS TESTING WERE OBTAINED AND ARE COSTLY ENOUGH TO RECOMMEND REPLACING PIPE INSTEAD OF HIRING TESTING SERVICES.
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES
EQUIPMENT:
FOURTEEN (14) TRANE AIR-COOLED CHILLERS
ELEVEN (11) TRANE AIR-COOLED CHILLERS INSTALLED IN 1990s
300 TON CENTRIFUGAL CHILLERS. PAST THEIR USEFUL LIFE & OBSOLETE. CAN NO LONGER GET PARTS FOR MACHINES
4160V MACHINES (NEW SERVICE WILL BE 480V)
FIVE (5) ARE IN WORKING CONDITION, REMAINING CHILLERS ARE OUT OF SERVICE
RECOMMEND REPLACING 4 ESSENTIAL CHILLERS WITH 300 TON CHILLERS, AND 4 OF 7 NON-ESSENTIAL MACHINES WITH 400 TON CHILLERS
THREE (3) TRANE AIR-COOLED CHILLERS INSTALLED IN 2010
400 TON SCREW CHILLERS
480V MACHINES
THE CHILLED WATER PIPING FROM CHILLER COMPOUND TO CHILLED WATER PUMP ROOM DOES NOT SHOW VISUAL SIGNS OF LEAKAGE EXCEPT AT SPECIFIC CONNECTIONS TO THE CHILLERS. GIVEN THE AGE OF THE PIPING NETWORK AND PAST CORROSION ISSUES DUE TO WATER QUALITY, QUOTES FOR NON-DESTRUCTIVE THICKNESS TESTING WERE OBTAINED AND ARE COSTLY ENOUGH TO RECOMMEND REPLACING PIPE INSTEAD OF HIRING TESTING SERVICES.
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES. PUMPS ARE OPERATING PROPERLY BUT ARE WELL PAST THEIR USEFUL LIFE. INSULATION MISSING FROM PIPING AND PUMPS HAVE RESULTED IN CONDENSATION AND SURFACE CORROSION.
SIX (6) CHILLED WATER PUMPS SERVING ESSENTIAL AND NON-ESSENTIAL
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING OPD CHILLED WATER CIRCUIT. NEW AND WILL NOT BE REPLACED.
LIMITED MAINTENANCE SPACE. MUST CLIMB OVER FIRST PUMP TO MAINTAIN SECOND PUMP.
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING NON-ESSENTIAL CHILLED WATER CIRCUIT
ONE PUMP IS NOT IN SERVICE, ONE PUMP REPLACED IN 2008
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING ESSENTIAL CHILLED WATER CIRCUIT
REPORTED MAINTENANCE ISSUES. PAST USEFUL LIFE (23 YEARS)
PUMPS ARE STARTED MANUALLY AND CONTROLS ARE NOT COMPATABLE WITH CONTROL ROOM SYSTEM
THE CHILLED WATER PIPING HEADERS SHOW MINOR SIGNS OF LEAKAGE
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES. PUMPS ARE OPERATING PROPERLY BUT ARE WELL PAST THEIR USEFUL LIFE. INSULATION MISSING FROM PIPING AND PUMPS HAVE RESULTED IN CONDENSATION AND SURFACE CORROSION.
SIX (6) CHILLED WATER PUMPS SERVING ESSENTIAL AND NON-ESSENTIAL
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING OPD CHILLED WATER CIRCUIT. NEW AND WILL NOT BE REPLACED.
LIMITED MAINTENANCE SPACE. MUST CLIMB OVER FIRST PUMP TO MAINTAIN SECOND PUMP.
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING NON-ESSENTIAL CHILLED WATER CIRCUIT
ONE PUMP IS NOT IN SERVICE, ONE PUMP REPLACED IN 2008
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING ESSENTIAL CHILLED WATER CIRCUIT
REPORTED MAINTENANCE ISSUES. PAST USEFUL LIFE (23 YEARS)
PUMPS ARE STARTED MANUALLY AND CONTROLS ARE NOT COMPATABLE WITH CONTROL ROOM SYSTEM
THE CHILLED WATER PIPING HEADERS SHOW MINOR SIGNS OF LEAKAGE
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES. PUMPS ARE OPERATING PROPERLY BUT ARE WELL PAST THEIR USEFUL LIFE. INSULATION MISSING FROM PIPING AND PUMPS HAVE RESULTED IN CONDENSATION AND SURFACE CORROSION.
SIX (6) CHILLED WATER PUMPS SERVING ESSENTIAL AND NON-ESSENTIAL
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING OPD CHILLED WATER CIRCUIT. NEW AND WILL NOT BE REPLACED.
LIMITED MAINTENANCE SPACE. MUST CLIMB OVER FIRST PUMP TO MAINTAIN SECOND PUMP.
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING NON-ESSENTIAL CHILLED WATER CIRCUIT
ONE PUMP IS NOT IN SERVICE, ONE PUMP REPLACED IN 2008
TWO (2) HORIZONTAL SPLIT CASE PUMPS
SERVING ESSENTIAL CHILLED WATER CIRCUIT
REPORTED MAINTENANCE ISSUES. PAST USEFUL LIFE (23 YEARS)
PUMPS ARE STARTED MANUALLY AND CONTROLS ARE NOT COMPATABLE WITH CONTROL ROOM SYSTEM
THE CHILLED WATER PIPING HEADERS SHOW MINOR SIGNS OF LEAKAGE
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES. BOILER VENDER INSPECTED EQUIPMENT.
FIRE TUBE BOILERS OF THIS AGE LAST BETWEEN 20 TO 35 YEARS DEPENDING ON MAINTENANCE AND WATER QUALITY. GIVEN REPORTS OF TUBE LEAKS AND PAST ISSUES WITH WATER QUALITY AND THE AGE OF THE EQUIPMENT, WE RECOMMEND REPLACING THE OLDER BOILER AND RENOVATING THE NEW BOILER.
STEAM PRODUCED WITH 2 FIRE-TUBE BOILERS
COCHRAN 1254 kW FIRE-TUBE BOILERS
INSTALLED IN 2001 AND 2013
REPORTED TUBE LEAKS, ISSUES WITH CHEMICAL TREATMENT
MANUAL BLOWDOWN VALVE
CONDENSATE RETURN TANK AND DEAREATOR REPLACED IN 2010
BLOW DOWN TANK INSTALLED IN 1980s
FOUR (4) FUEL OIL PUMPS INSTALLED IN 1980s
WATER TREATMENT REPLACED IN 2010
HOT WATER PRODUCED WITH 6 CALORIFIERS
FOUR (4) SERVE DOMESTIC HW (N+2)
TWO (2) INSTALLED IN 2010
TWO CURRENTLY NOT IN SERVICE
TWO (2) SERVE LAUNDRY, INSTALLED IN 2010
STEAM PIPES AND VALVES SHOW VISIBLE SIGNS OF LEAKAGE AND TEMPORARY PATCHES
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES. BOILER VENDER INSPECTED EQUIPMENT.
FIRE TUBE BOILERS OF THIS AGE LAST BETWEEN 20 TO 35 YEARS DEPENDING ON MAINTENANCE AND WATER QUALITY. GIVEN REPORTS OF TUBE LEAKS AND PAST ISSUES WITH WATER QUALITY AND THE AGE OF THE EQUIPMENT, WE RECOMMEND REPLACING THE OLDER BOILER AND RENOVATING THE NEW BOILER.
STEAM PRODUCED WITH 2 FIRE-TUBE BOILERS
COCHRAN 1254 kW FIRE-TUBE BOILERS
INSTALLED IN 2001 AND 2013
REPORTED TUBE LEAKS, ISSUES WITH CHEMICAL TREATMENT
MANUAL BLOWDOWN VALVE
CONDENSATE RETURN TANK AND DEAREATOR REPLACED IN 2010
BLOW DOWN TANK INSTALLED IN 1980s
FOUR (4) FUEL OIL PUMPS INSTALLED IN 1980s
WATER TREATMENT REPLACED IN 2010
HOT WATER PRODUCED WITH 6 CALORIFIERS
FOUR (4) SERVE DOMESTIC HW (N+2)
TWO (2) INSTALLED IN 2010
TWO CURRENTLY NOT IN SERVICE
TWO (2) SERVE LAUNDRY, INSTALLED IN 2010
STEAM PIPES AND VALVES SHOW VISIBLE SIGNS OF LEAKAGE AND TEMPORARY PATCHES
CONDITION ASSESSMENT: PERFORMED VISUAL INSPECTION OF EXISTING EQUIPMENT AND INTERVIEWED STAFF REGARDING MAINTENANCE HISTORY/PRACTICES. BOILER VENDER INSPECTED EQUIPMENT.
FIRE TUBE BOILERS OF THIS AGE LAST BETWEEN 20 TO 35 YEARS DEPENDING ON MAINTENANCE AND WATER QUALITY. GIVEN REPORTS OF TUBE LEAKS AND PAST ISSUES WITH WATER QUALITY AND THE AGE OF THE EQUIPMENT, WE RECOMMEND REPLACING THE OLDER BOILER AND RENOVATING THE NEW BOILER.
STEAM PRODUCED WITH 2 FIRE-TUBE BOILERS
COCHRAN 1254 kW FIRE-TUBE BOILERS
INSTALLED IN 2001 AND 2013
REPORTED TUBE LEAKS, ISSUES WITH CHEMICAL TREATMENT
MANUAL BLOWDOWN VALVE
CONDENSATE RETURN TANK AND DEAREATOR REPLACED IN 2010
BLOW DOWN TANK INSTALLED IN 1980s
FOUR (4) FUEL OIL PUMPS INSTALLED IN 1980s
WATER TREATMENT REPLACED IN 2010
HOT WATER PRODUCED WITH 6 CALORIFIERS
FOUR (4) SERVE DOMESTIC HW (N+2)
TWO (2) INSTALLED IN 2010
TWO CURRENTLY NOT IN SERVICE
TWO (2) SERVE LAUNDRY, INSTALLED IN 2010
STEAM PIPES AND VALVES SHOW VISIBLE SIGNS OF LEAKAGE AND TEMPORARY PATCHES
TWO FUEL OIL STORAGE TANKS USED FOR EMERGENCY POWER FOR GENERATORS AND BOILERS
MECHANICAL INTEGRETY OF TANKS WAS NOT INSPECTED. VISUAL INSPECTION SHOWS NO OBSERVABLE ISSUES.
FILL STATIONS SHOWS ISSUES WITH LEAKS AT FILL STATION AND WHERE FUEL OIL DELIVERY TRUCK CONNECTS.
VISIBLE ISSUES WITH FUEL OIL LEVEL INDICATORS AND WITH GATE ISOLATION VALVE. EXISTING CONTROLS ARE NOT COMPATABLE WITH SYSTEM IN CONTROL ROOM.
LACK OF CONCRETE CONTAINMENT PAD.
TWO OXYGEN TANK ASSEMBLIES.
ONE SYSTEM IS NOT IN SERVICE, ONE NEW SYSTEM.
PIPING SHOWS VISIBLE SIGNS OF CORROSION
CONTROLS SYSTEMS ARE NOT COMPATABLE WITH CONTROL ROOM CONTROLS.
DISTRIBUTION SYSTEMS INCLUDE
STEAM & CONDENSATE
ESSENTIAL & NON-ESSENTIAL CHILLED WATER
DOMESTIC COLD WATER
LAUNDRY COLD WATER
DOMESTIC HOT WATER
LAUNDRY HOT WATER
MULTIPLE LEAKS AND PATCHES IN PIPING NETWORK. UNSAFE CONDITIONS EXIST IN TUNNEL WITH STEAM PIPING SHOWING ISSUES WITH PIPE EXPANSION.
RECOMMEND REPLACING ALL PIPING BETWEEN STEAM AND CHILLED WATER PRODUCTION AND HOSPITAL