Brookwood Secure Center Chiller Replacement

Scope of Project:
The project, performed for NYS OGS, included the removal and replacement of the existing 120-ton chiller serving the Brookwood Secure Center located in Claverack, NY. The existing chiller was 21 years old and was unable to meet the cooling load of the facility. Additionally, the R-22 refrigerant utilized by the chiller was becoming increasing costly to replace due to a lack of availability.

Summary:
Engineering services included performing an energy load analysis and system review of the existing chilled water distribution system to verify the capacity of the replacement chiller. During the analysis, it was discovered that the original chiller plant design intended to install two 120-ton chillers to support the main building cooling load. Following a verification of the overall cooling load using Trane Trace software, it was agreed to install two 120-ton chillers to support the full cooling load of the facility. Per the client request, the replacement chillers were designed to utilize multi-circuited scroll compressors for ease of maintenance and replacement. Additionally, the remote condensers were designed to make cleaning of the condenser coils easy and accessible. The new units utilized environmentally friendly and readily accessible R-410a refrigerant.

Scheduling of the project became a critical aspect of the overall project complexity. Since the cooling system had a limited shut down period during the winter months, a tight milestone schedule was required to guarantee cooling was available for the building occupants by April 1st. By building the project in 3D Revit software during design, the team was able to create a near as-built condition that limited field changes and project delays during construction.

Other key aspects to the design was to provide a chiller plant that was simple to service. Due to Brookwoods’ remote location, the facility has had difficulty in the past getting qualified technicians to service their equipment. With each chiller designed with multiple independent refrigerant circuits and off the shelf scroll compressors, the new system incorporated design and maintenance aspects that would limit shutdown time and system capacity during routine maintenance and repair.

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Ten Eyck Cooling Tower Replacement

Scope of Project:
The project, performed for NYS OGS, included the removal and replacement of the roof mounted cooling towers serving the 16 story Ten Eyck Office building located in Albany, NY. The existing cooling towers, which supplied cooling to the main building heat pump loop, were 22 years old and in need of replacement. Moreover, the 1970’s steel dunnage supporting the existing cooling towers was failing to the point of becoming a hazard to the occupants if left untreated.

Summary:
Engineering services included performing an energy load analysis on the entire 16 story building to verify the capacity of the replacement cooling towers. Two new cooling towers, each consisting of 800 tons of cooling capacity, were designed and installed on new galvanized coated steel dunnage. Per the client request, the replacement cooling towers were designed to provide better accessibility for maintenance and service.

Project scheduling and phasing became a critical aspect of the overall project complexity. Since the building utilized the heat pump loop
year-round for heating and cooling, a long term shut down of the heat pump loop was not feasible. To account for this, a weekend shut down was performed to install 18-inch butterfly valves for isolating the existing towers from the main heat pump loop. The removal of the existing towers and installation of the new units was also limited to a two weekend shut-down in the middle of the winter. This required close coordination with the City of Albany to develop a detailed traffic control plan to shut-down Pearl Street during crane operations.

Other key aspects to the design included limiting the transmission of sound and vibration from the towers to the existing building structure. Upon completion of the project, sound and vibration levels were found to be lower than the previous tower installation.

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GE Building 66 Exterior

Scope of Project:
General Electric converted building 66 from an industrial manufacturing building to the new battery manufacturing building and 60,000 square feet of new office space.

Summary:
A new HVAC system was designed for the office space utilizing new gas rooftop units. Individual temperature control zones were derived by a variable air volume (VAV) control system. VAV boxes with hot water reheat coils are installed to serve the zones throughout the office spaces. A central heating hot water plant provides hot water for distribution throughout the building. This boiler is sized to provide the entire heating hot water load to support the reheat coils and fin radiation installed in the system. A single base-mounted circulating pump will be installed to serve the hot water distribution system piping and terminal units. Some fin tube radiation has been designed to serve high heat loss areas such as lobby perimeter to offset large glazing areas. Vestibules are supplied with hot water cabinet heaters.

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