Hospital!ExpansionandMechanical!Upgrades!! Deliver$500...

Hospital Expansion and Mechanical Upgrades

Deliver $500,000 in Energy Savings

150,000 SQ. FT. BLODGETT HOSPITAL CAMPUS EXPANSION

CAMPUS BOILER AND CHILLED WATER PLANT UPGRADES

NET DECREASE ION ENERGY CONSUMPTION

www.synergy-‐engineers.com

150,000 Sq. Ft. Inpatient Addition

Synergy Maximizes Building Performance from Start to Finish.

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Summary

Spectrum Health Blodgett Hospital, East Grand Rapids, Michigan $98 Million Renovation and Expansion Project LEED Silver Chiller and Boiler Plant Upgrades

Project Background Spectrum Health is one of the largest providers of health care services in Michigan, offering a continuum of healthcare services across multiple campuses throughout West Michigan. Synergy Consulting Engineers was selected to provide systems analysis and design of approved recommendations of the Spectrum Health Blodgett Hospital’s Boiler Plant and Chilled Water Plant that service the 800,000 Sq. Ft. campus. Synergy also provided commissioning services for the new 150,000 Sq. Ft. five-‐story inpatient addition with 120 patient rooms and support spaces, and main campus renovations including new state-‐of-‐the-‐art operating rooms, 164 private rooms, and a 36-‐bed post-‐anesthesia care unit, or PACU – one of the largest in the country.

ImpactSynergy delivers performance-‐based engineering solutions for Healthcare owners and operators interested in pursuing energy efficiency, energy management and planned initiatives for capital improvements. For Spectrum Health, the performance and efficiency of upgrades made to the Boiler and Chilled Water Plants at Blodgett Hospital made it possible to improve services for the main campus and the new 150,000 Sq. Ft. inpatient addition, with an actual Net Decrease in Energy Consumption and an Annual Savings of nearly $500,000.

Initial Evaluation/Study The purpose of the initial study was to present an evaluation of the existing plants and to determine if each would meet the immediate and future demands of the hospital. This report also included an energy analysis that compared the efficiency, operating costs, and useful life of the existing chillers and boilers with new high performance/efficient systems and design strategies.

The content of this study is based on: 1. Field observations2. Archive / Design drawings3. Interviews with maintenance personnel to ascertain operational concerns and deficiencies

with the existing chiller plant4. Test & Balance reports5. Current utility rates6. Accepted Engineering practice

Scope of Study • The study estimated the existing demand of the hospital by calculating the actual load.• The new addition estimated load is added to the total existing load to determine if the existing plants

have sufficient capacity.• The condition of the equipment in each plant was evaluated to determine the viability of continued use

and required improvements.• Multiple options were then evaluated on a life cycle basis to determine the best option for improvements

that met the needs of the facility including the new addition and maximize energy efficiency.

As part of the Energy Center renovations, the chiller renovations involved removal and replacement of two of the four existing chillers. Using the most recent air and hydronic balance reports, design data, and by interviewing energy plant personnel, the cooling load of the hospital was determined. The results show that in order to meet this cooling demand on design cooling days, there would need to be 2,700 tons of nominal chiller capacity in use.

E Existing Equipment Data

CH-‐1 Absorption Chiller Carrier 1,000 tons

CH-‐2 Centrifugal Chiller Trane 460/3 1,200 tons

CH-‐3 Absorption Chiller Trane 1,000 tons

CH-‐4 Screw Chiller Trane 460/3 300 tons

Winter Cooler Heat Exchanger Alfa Laval -‐ 400 tons

CT-‐1 Cooling Tower Marley 460/3/74 1,650 gpm





Condensing Water Pump P-‐1 Bell & Gossett 460/3/104 3,360 gpm @ 80’ hd



Chilled Water Pump P-‐1 Bell & Gossett 460/3/74 2,680 gpm @ 70’ hd



Any changes to the chilled water plant had to produce a minimum of 2,700 to 2,900 tons of cooling. The 2,700 to 2,900 tons of required capacity is based on 2,000 to 2,250 tons of current load and 650 tons of future required load. With this chiller capacity, the existing facility load and the new addition load is sustainable.

Multiple options were evaluated to meet these demands (see chart below)

Summary of Recommended Options Chiller Option A Option B Option C Option D X-‐CH-‐1 (Carrier Absorber) D D D D X-‐CH-‐2 (Trane Centrifugal) B B P B X-‐CH-‐3 (Trane Absorber) D D B D X-‐CH-‐4 (Trane Screw) P P P P New 1,200 ton P P NR NR New 1,200 ton P NR NR NR New 1,500 ton NR P P P New 1,500 ton NR NR NR P Primary Tonnage 2,700 tons 3,000 tons 3,000 tons 3,300 tons Total Tonnage w/Backup 3,900 tons 4,200 tons 4,000 tons 4,500 tons Estimated Costs $1,255,000 $1,533,000 $1,163,000 $1,810,000

P = Primary Chiller B = Backup Chiller D = Demolition NR = Not Required



One 1200 ton and one 1500 ton centrifugal chiller was installed. The new chillers were needed, in part, for the added capacity of the new 150,000 square foot addition to Blodgett hospital and were sized to allow for addition capacity and redundancies.

The following items are additional improvements that further increased efficiency of the chilled water plant:

• Increase Capacity of Winter Cooler• Control Valve on Steam Lines for Cooling Towers

Basin Heating• Variable Primary Pumping• Variable Secondary Pumping• Variable Primary Only Pumping• Temperature Control System• Thermal Storage

• Series Chillers• Condenser Heat

Recovery• Decrease Steam

Boiler Plant Capacity• Remote Condenser

Water Basin / DrainBack Tank

The energy economics were simulated using the Trane Trace 700 simulation program. All costs were calculated over a study life of 40 years. Estimate for equipment installation cost was based on: Install cost ($)= equipment cost ($)* 1.5

Basis of Calculations Utility Rates Electricity $0.0650/KWH Gas $0.975/Therm

Based on the results from the economic analysis (first cost ranking and economic ranking), option A actually ranked higher than option B. However, option B was determined to be the best option. Although utility costs and life cycle costs are lower with option A, when the load exceeds 2,700 tons the backup centrifugal chiller will be required to operate to meet the demand. Therefore if a chiller were to fail under these conditions the chilled water plant would be unable to adequately maintain the chilled water setpoint. With option B there is an additional 300 tons of capacity at relatively the same utility cost. The utility costs are relatively the same because there are more operating hours on the more efficient centrifugal chillers.

Pump Replacement Included as part of the Energy Center Renovations, the entire chilled water and condensing water pump packages have been updated and replaced. These pumps are used to supply the entire buildings cooling demand to the various air handler units throughout the hospital. The pumping system change required the hospital to change from a primary/secondary system with several booster pumps located throughout the hospital to a primary pumping system utilizing 3 larger pumps. The pumps were connected to Variable Frequency Drives (VFD's) which control the speed of the pumps, allowing the flow of water to match the exact load that is needed. In turn, this has reduced the over-‐all electrical demand to power the pumps.



Ice Storage Ice storage, or thermal storage, is a fairly old concept that involves the shifting of electrical loads from more expensive peak demand hours to less expensive non-‐peak demand hours through the nighttime production of ice. The ice is then stored throughout the day and used to cool the buildings chilled water supply, reducing the demand on the chillers when cooling loads are at their highest. While a direct energy efficiency gain is not realized from the production of ice, the decreased demand on the chillers, which are the number one consumer of electricity in any major facility, is reduced. In less than a year and a half, the savings from the ice storage system has more than offset the cost associated with the ice storage installation. The use of ice storage can produce 1944 ton hours of cooling for the facility.

Plate Heat Exchanger In conjunction with the chiller and cooling tower replacement, the Energy Center plate heat exchanger has also been replaced. Because a building always has a latent heat load regardless of the time of year, a heat exchanger is used as a means of "free cooling" in the colder months on internal heating loads from MRI units, data rooms, and machine rooms. When temperatures are 48 degrees or less outside we are able to divert the flow of water through the plate heat exchanger, reducing the over-‐all demand on the chillers. Since the Plate Heat Exchanger has been operational, an additional 300 tons of cooling can be diverted, allowing the chillers to remain idle during this time.

Cooling Tower Replacement Of the existing five Marley cooling towers, four were completely removed. Two new CCS cooling towers now perform the job of the previous four. The cooling towers work through evaporative cooling, using the colder outside air temperatures to cool the water flowing through the towers. The towers are an updraft or counterflow high efficiency style of cooling tower, that will increase heat rejection capacity, and also reduce the chemical and maintenance costs associated with cooling towers. In a year-‐to-‐year comparison, an estimated 6.83 million gallons of water consumption has been reduced and we have seen a 3.2 million gallon savings from blow down in the towers. Along with water savings, 82 gallons of cooling water treatment was eliminated, saving $2,288 that year.

Air Handler Replacement Since 2008, twelve of the hospitals existing air-‐handling units have been completely replaced. The new custom-‐designed units were brought into the building in multiple sections or assembled completely on site. The fans in each unit are equipped with a VFD control module that allows the fan to operate at the exact air volume needed. Along with the VFD's, all AHUs are tied into our Building Automation System, or BAS for short (see below for a more detailed description of this system). With all of the new technology that was put into these units, our Facilities Team was able to have a better understanding of the buildings’ heating and cooling needs and can respond to issues at the click of a button.

Building Automation System (BAS) In conjunction with the AHU replacements, controls for the units were also updated. Through the use of a Trane Building Automation System, Spectrum Health Facilities team members are able to monitor the running conditions of all AHU's throughout the facility from a centrally located

computer. This ensures that all of the units are functioning to their designed specifications, in turn, increasing the over-‐all efficiency and energy savings of the unit.



The Boiler Plant The existing boiler plant consists of (5) existing water tube steam boilers (300 HP|16,000 #/hr each – 80,000 #/hr combined) that provide the steam to the existing absorption chillers, steam heating coils, steam radiators, heating water heat exchangers, humidifiers, and domestic water heat exchangers. The two newest boilers are 1974 vintage. The three older boilers are 1965 vintage. Based upon the steam produced (measured by steam meter) and associated firing rates the efficiency of each boiler is approximately 50-‐60%.

When considering the existing steam demand (without the absorption chillers) and the future demand of the addition, it is our recommendation to plan to replace all (5) existing boilers with (7) new Vertical Tube, Fulton, 150 HP, Steam Boilers. The Fulton Boilers are 85% efficient, high performance boilers with a total connected capacity of 41,400 #/hr. Due to the lower capacity of each boiler, the steam supply will be matched effectively and evenly to the steam demand.

Table 1 – Existing Steam Demand Steam

( #/hr)

Heating Water (MBH)

Steam Heating (AHU Heating Coils & Steam Convectors)

Heating Hot Water (via Steam|Hot Water Heat Exchangers)

AHU Heating Coils & Reheat Coils, Radiant Heating

Domestic Hot Water (via Steam|Hot Water Heat Exchangers)

Humidification

Food Service

Sterilization

TOTAL 22,000 #/hr

Table 2 – Future Steam Demand ( Inc lud ing New Add i t ion )

Steam

( #/hr)

Heating Water (MBH)

Steam Heating (AHU Heating Coils & Steam Convectors)

Heating Hot Water (via Steam|Hot Water Heat Exchangers)

AHU Heating Coils & Reheat Coils, Radiant Heating 8,311 MBH

Domestic Hot Water (via Steam|Hot Water Heat Exchangers) 2,900 #/hr

Humidification

Food Service

Sterilization

TOTAL 34,000 #/hr



Table 3 – Existing Boiler Data

Manufacturer | Model Install Date Capacity

B-1 Cleaver Brooks 1974 16,000 #/hr





Connected Capacity 80,000 #/hr

Table 4 – New Boi ler Data

Manufacturer | Model Capacity

B-1 ( Vertical Fire Tube ) Fulton | VPM 150 5,175 #/hr








Connected Capacity 41,400 #/hr

Beyond the boilers, other systems included in the study include:

• Boiler Feed Water System• Boiler Blow-‐down System• Ventilation|Combustion Air• Facility Energy Management Control System• Steam, Steam Condensate, and Heating Water Piping• Steam | Hot Water Heat Exchangers• Prioritized Recommendations



Priority Recommendation 1. Install (3) new modular steam boilers and remove B-‐1, B-‐2, & B-‐3.2. Install new boiler feed water system.3. Install (5) additional modular steam boilers and remove B-‐4 & B-‐5 (A section of the existing roofwill need to be removed if this is not complete in conjunction with the chiller plant improvement).

4. Install new boiler stack economizer in new boiler breeching. Abandon the existing chimneys.5. Take pipe samples of the heating piping to assess their condition. Focus on mains and fittings.6. Replace existing piping as required.7. Inspect hot water tubing in existing heat exchangers (check tubing thickness and tubing corrosion)8. Replace existing heat exchangers as required.9. Test the existing exhaust and intake airflows10. Add steam pressure gauges to each side of the PRV’s.11. Tear down two existing Chimneys

Implementation All five existing Cleaver Brooks boilers were replaced with 8 new Vertical Tube, 150 HP, Fulton steam boilers. The new Fulton boilers are a high efficiency boiler with a smaller nominal capacity than the existing, allowing the steam capacity and demand to be matched much more effectively. The Fulton boilers are also dual fired boilers, allowing for operation on both natural gas and fuel oil.

LEED This project was commissioned in accordance with LEED NC v2.2 EA Prerequisite 1 EA Cr. 3" Synergy also provided commissioning services for all major systems in the facility. Synergy employs one of the most comprehensive Commissioning process available to ensure that the systems installed perform as designed and met the owner’s project requirements.

Looking at the numbers: Blodgett 2009/2010 Actual

Blodgett 2009/2010 at 2010/11 Pricing

Blodgett 2010/2011 Actual

Square Footage 594,143 594,143 788,533

Cost / KWH $0.0776 $0.0869 $0.0869

Total KWH consumed 22,419,481 22,419,481 24,107,135 Total KWH cost / year $1,739,752 $1,948,253 $2,094,910

Cost / MCF $7.7737 $5.8928 $5.8928

Total MCF consumed 128,612 128,612 141,626 MCF transport cost $130,744 $130,744 $117,968

Total Gas Cost / year $1,130,535 $888,629 $952,542

Total Energy Cost $2,870,287 $2,836,882 $3,047,452

Total Cost per square foot $4.8310 $4.7747 $3.8647 Projected Energy costs before boiler and chiller renovations $2,836,882

Projected Energy costs minus the cost of the Blodgett expansion $2,296,191 Blodgett Renovation Energy Savings $540,691

SILVER



Hospital!ExpansionandMechanical!Upgrades!! Deliver$500...

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