Butler Memorial Hospital
Butler Memorial Hospital
New Inpatient Tower
Butler, PA
Matthew Geary
Mechanical Option
Advisor: Dr. William Bahnfleth
Butler Memorial Hospital
Introduction
Building Statistics
•Location: Butler, PA
•Size: 200,000 sqft Inpatient Addition
•Occupancy: Hospital, Surgery, Recovery, & CCU
•Cost: 93 Million
•Levels: 2 Below Grade, 5 Above Grade
•Construction: September 2008 – July 2010
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Aerial View of Property
Matthew Geary | Mechanical
•Delivery: Design-Bid-Build
*Note: The floor above the 3rd floor is the 5th, not the 4th.floor
Introduction
Butler Memorial Hospital
Project Team
•Owner: Butler Healthcare Providers
•Construction Manager: Turner Construction
•Mechanical Contractor: Limbach Facility Services
Typical Patient’s Room
Matthew Geary | Mechanical
North-West Facade
Chapel
Typical Operating Room
•MEP Engineer: HGA
Butler Memorial Hospital
Building Design
Architecture
•Exterior Facade
•Aluminum & glass curtainwall
•Red brick veneer
•Roofing
Nurses’ Station
•Mechanically fastened thermoplastic membrane
•Interior
•Contemporary vibe
•Patient rooms along perimeter
•Grand entryway atrium
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Entryway Atrium
Main Entrance
Butler Memorial Hospital
Building Design
Structural System
•Foundation
•Concrete caissons & grade beams
•Poured concrete foundation walls
•Structural Steel System
•Wide flange structural steel beams and columns
•Columns laterally braced with K frame braces
•Composite metal deck with shear studs
•3-1/2” concrete topping
Exterior Walls
Poured Foundation Walls
•Wall Construction
•6” steel studs, gypsum board on both sides
•2” rigid insulation, face brick
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Caisson Drilling
Structural Steel
Electrical System
Building Design
Butler Memorial Hospital
•Entry Service
•Feeds from existing hospital
•2,500 KVA transformer in mechanical room
•3 Phase 480Y/277 V distribution
•Electrical Distribution
•Electrical rooms on each level deliver 208Y/120V & 480Y/277V
•3 Ф 480 V
•Heavy equipment, motors, & fans
•1 Ф 277 V
•Fluorescent lighting
Switchboard
•1 Ф 120 V
•Incandescents, halogens, receptacles, & office equipment
•Emergency Power
•(2) 800 KW Caterpillar generators
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Emergency Generator
Original Mechanical System
Butler Memorial Hospital
Mechanical Overview
•Variable air volume w/ reheat
•33% outdoor air
•(3) rooftop air handlers supply majority of spaces
•Loop design, provides redundancy
•Served by (2) centrifugal chillers
Centrifugal Chiller
Primary Rooftop Air-Handler
•(2) smaller rooftop air handlers supply OR
•Independent of primary system
•Served by (1) scroll chiller
•(2) 7,200 MBH gas-fired boilers
•Radiant panels along perimeter of patient rooms
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Cooling Towers
Gas Fired Boiler
Original Mechanical System
Butler Memorial Hospital
Air-Side Overview
•Primary Rooftop Air Handlers (AHU-1, 2 & 3)
Primary
Operating
Rooms
•(3) 62,000 CFM Air Handlers
•Serves majority of New Inpatient Tower
Mechanical
Rooms
•Operating Room Rooftop Air Handlers (AHU-4 & 5)
•(2) 18,500 CFM Air Handlers
•Serves operating rooms and support space
Primary Rooftop Air-Handler
•Mechanical Room Air Handlers ( AHU-6, 7, & 8)
•Serve specialty mechanical rooms
Air Handler Diagram
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**Note: AHU-8 not shown in diagram
•Vary from 4,000 – 5,000 CFM
Original Mechanical System
Butler Memorial Hospital
Chilled Water
•Primary Loop (CH-1 & 2)
•(2) 400 ton water cooled centrifugal chillers
•Serves primary AHU’s 1-3 & Mech. AHU’s 6-8
•Serves as back-up for operating room AHU’s
•(2) Primary pumps
•(2) VSD Secondary pumps
•Operating Rooms Loop (CH-3)
400 Ton Centrifugal Chiller
•(1) 120 ton air-cooled scroll chiller
•Serves operating rooms and support space (AHU-4 & 5)
•Supply CHW temperature at 34°F
•(1) Primary pump
Matthew Geary | Mechanical
Chilled Water Diagram
Original Mechanical System
Butler Memorial Hospital
Condenser Water
•(1) Packaged double cell Marley cooling tower
•Serves centrifugal chillers (CH-1 & CH-2)
•(2) constant speed pumps
•(2) VFD radial cooling tower fans
Double Cell Marley Cooling
Tower
Condenser Water Diagram
Matthew Geary | Mechanical
Original Mechanical System
Butler Memorial Hospital
Heating Water
•(2) 7,200 MBH Gas-fired boilers
•Primary Loop
•(2) primary pumps
•3 way valve controls flow rate and temperature of
supply water to secondary loop
•Secondary Loop
Gas-Fired Boiler
•(2) VSD secondary pumps distribute to loads
•Distributes to AHU-1:8, terminal boxes, duct heaters,
& radiant ceiling panels
•Inline booster pumps at coils in AHU’s
Matthew Geary | Mechanical
Heating Water Diagram
Original Mechanical System
Butler Memorial Hospital
Heating Water
•(2) 7,200 MBH Gas-fired boilers
3 Way
Control
Valve
•Primary Loop
•(2) primary pumps
•3 way valve controls flow rate and temperature of
supply water to secondary loop
•Secondary Loop
Gas-Fired Boiler
•(2) VSD secondary pumps distribute to loads
•Distributes to AHU-1:8, terminal boxes, duct heaters,
& radiant ceiling panels
•Inline booster pumps at coils in AHU’s
Matthew Geary | Mechanical
Heating Water Diagram
Butler Memorial Hospital
Original Mechanical System
Energy Consumption
•Receptacles and Lighting: constant loads, unaltered
•Fan energy is largest consumer of HVAC energy
followed by cooling energy
•Improvement Ideas
•Reduce fan energy by utilizing DOAS
•Reduce outside air
•Water side free cooling
Matthew Geary | Mechanical
Butler Memorial Hospital
Mechanical Redesign
Goals
•Reduce Energy & Life Cycle Costs
•Increase Indoor Air Quality
•Maintain Redundancy & Reliability
•Decrease Carbon Footprint
Matthew Geary | Mechanical
Butler Memorial Hospital
Mechanical Redesign
Main Features
•Dedicated Outdoor Air System
•Semco Pinnacle Unit
•Figure 1
•Active Chilled Beams
•Flaktwoods/Semco Series IQIC & IQCA
•Figure 2
Fig.1
Fig. 2
•Water Side Free Cooling
•Increased efficiency with chilled beams
•Figure 3
Matthew Geary | Mechanical
Fig. 3
Butler Memorial Hospital
Mechanical Redesign
Advantages
•Decreased Energy Costs
•Less airflow, less fan energy
•Water side economizer reduces chiller hours
•Increased Reliability
•Constant ventilation ensures high IAQ
•Simple throttling valves vs. complicated terminal box controls
•No moving parts in chilled beam, easier maintenance
•Reduced First Cost
•Chillers, Ductwork, Terminal Boxes & Air Handlers
Matthew Geary | Mechanical
Butler Memorial Hospital
Mechanical Redesign
Design Loads
•Cooling Loads
•Primary Air Handler Load – 178 tons
•Chilled Beam Load – 138 tons
•Heating Loads
•Primary Air Handler Load – 3,105 Mbh
•Chilled Beam Load – 2,255 Mbh
•Ventilation Rate – 38,500 CFM
Matthew Geary | Mechanical
**Note: Loads are for Primary System only; OR loads not included
Mechanical Redesign
Butler Memorial Hospital
•Air Side
•Eliminated (3) primary rooftop AHU
•Added (1) 42,000 CFM DOAS AHU
•Water Side
•Eliminated (2) 400 ton centrifugal chillers
•Eliminated original primary and secondary pumps
•Added (3) 180 ton screw chillers
•Added (3) primary and (3) secondary pumps
•Added plate & frame heat exchanger
•Added chilled beams
Matthew Geary | Mechanical
*Note: Secondary system supplying operating rooms was unaffected
Butler Memorial Hospital
Mechanical Redesign
Normal Operation
Primary AHU Loop
Primary Chilled Beam Loop
Matthew Geary | Mechanical
Operating Room AHU Loop
Butler Memorial Hospital
Mechanical Redesign
Free Cooling Application
Primary AHU Loop
Primary Chilled Beam Loop
Matthew Geary | Mechanical
Operating Room AHU Loop
Butler Memorial Hospital
Mechanical Redesign
Chiller 1 (or 2) Fails
Primary AHU Loop
Primary Chilled Beam Loop
Matthew Geary | Mechanical
Operating Room AHU Loop
Butler Memorial Hospital
Mechanical Redesign
PCHWP-1 Fails
Primary AHU Loop
Primary Chilled Beam Loop
Matthew Geary | Mechanical
Operating Room AHU Loop
Butler Memorial Hospital
Mechanical Redesign
SCHWP-1 also Fails
PCHWP-4 & SCHWP-3 can supply either loop
Primary AHU Loop
Primary Chilled Beam Loop
Matthew Geary | Mechanical
Operating Room AHU Loop
Butler Memorial Hospital
Mechanical Redesign
Secondary Loop Fails
Primary/Secondary AHU Loop
Primary Chilled Beam Loop
Matthew Geary | Mechanical
Butler Memorial Hospital
Mechanical Redesign
Energy Comparison
Primary/Secondary AHU Loop
Annual Energy Savings = 3,245 MMBtu
Matthew Geary | Mechanical
Butler Memorial Hospital
Mechanical Redesign
Energy Cost Savings
Annual Cost Savings = $36,140.00
Matthew Geary | Mechanical
Butler Memorial Hospital
Matthew Geary | Mechanical
Mechanical Redesign
Reduced Ductwork
Butler Memorial Hospital
Matthew Geary | Mechanical
Mechanical Redesign
Reduced Ductwork
Butler Memorial Hospital
Mechanical Redesign
Chilled Water Distribution Piping
•Chilled beams will need chilled water supply
•Design Criteria
• < 1” – Type L drawn copper
• > 1” – Schedule 40 steel
•Sizing Criteria
• < 2” – Max velocity 4 ft/s
• > 2” – Max head 4’/100’ piping
Matthew Geary | Mechanical
Butler Memorial Hospital
Mechanical Redesign
Chilled Water Distribution Piping
Matthew Geary | Mechanical
Butler Memorial Hospital
Matthew Geary | Mechanical
Mechanical Redesign
First Cost Summary
Net Savings = $276,906.00
Butler Memorial Hospital
Mechanical Redesign
Life Cycle Cost Analysis
First Cost Savings = $276,906.00
Annual Energy Savings = $36,140
Matthew Geary | Mechanical
Butler Memorial Hospital
Structural Breadth
Proposed Redesign
•Elimination of AHU-1 & AHU-3
•Reduced roof dead load in these areas
•Resize structural steel
•AHU-2 Replaced by DOAS Pinnacle Unit
•Located in same area to avoid ductwork penetration issues
•Comparable dimensions and weight
Matthew Geary | Mechanical
Butler Memorial Hospital
Matthew Geary | Mechanical
Structural Breadth
AHU-1 Beam Redesign
Butler Memorial Hospital
Matthew Geary | Mechanical
Structural Breadth
AHU-3 Beam Redesign
Butler Memorial Hospital
Matthew Geary | Mechanical
Structural Breadth
DOAS Air handler Location
Steel Summary
**Note: Cost data taken from RS Means
Butler Memorial Hospital
Matthew Geary | Mechanical
Electrical Breadth
Electrical Savings = 426 kVA
Comparison Summary
Butler Memorial Hospital
Summary
Goals Attained
•Reduce Energy & Operation Costs
•Saved $277,000 First Costs
•Saved $36,000 Operational Costs
•Increase Indoor Air Quality
•DOAS ensures appropriate amounts of outdoor air
•Maintain Redundancy & Reliability
•Designed with inherent redundancy in all components
•Decrease Carbon Footprint
•Decreased emissions of CO2, SO2 & NOx
Matthew Geary | Mechanical
Butler Memorial Hospital
Summary
MAE Incorporation
•AE 558 Central Heating
• Calculating Payback Period
•AE 557 Central Cooling
•Water-Side Free Cooling
•Centralized vs. Distributed Pumping
•AE 542 Indoor Air Quality
•Improvement of IAQ
Matthew Geary | Mechanical
Acknowledgments
•Butler Healthcare Providers
•Turner Construction – Megan Corrie
•HGA – Tim Andersen & Michael Woodson
•HF Lenz – David Miller
•Limbach Facility Services – John Hilf
•Semco – Matt Pemberton, Randy Phillips, & Thomas Kitchen
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Butler Memorial Hospital
QUESTIONS?
Matthew Geary | Mechanical
Butler Memorial Hospital
Alternate Design
First Cost Summary
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Matthew Geary | Mechanical
Net Savings = $60,057.00
Butler Memorial Hospital
Mechanical Redesign
Semco Pinnacle Application Guide
Matthew Geary | Mechanical
Semco Pinnacle Unit
Butler Memorial Hospital
Mechanical Redesign
Semco Pinnacle Application Guide
Matthew Geary | Mechanical
Semco Pinnacle Unit
Butler Memorial Hospital
Mechanical Redesign
Semco Pinnacle Application Guide
Matthew Geary | Mechanical
Semco Pinnacle Unit
Butler Memorial Hospital
Mechanical Redesign
Semco Pinnacle Application Guide
Matthew Geary | Mechanical
Semco Pinnacle Unit