Straumann USA
60 Minuteman Road
Andover, MA
Kevin Kaufman
Mechanical Option
The Pennsylvania State University
Architectural Engineering
Presentation Outline
Straumann
USA
 INTRODUCTION
 Existing
Conditions

 Design
 Objectives

 Mechanical
Alternatives

 Electrical
 Breadth

 Construction
Breadth

 Life Cycle
 Cost Analysis

•
 Conclusions

Kevin Kaufman
Mechanical Option
Existing conditions
Design Objectives
Mechanical Alternatives
Electrical Breadth
Construction Breadth
Life Cycle Cost Analysis
Conclusions
Building Background
Straumann
USA
Introduction
 EXISTING
 CONDITIONS
 Design
 Objectives
 Mechanical
Alternatives
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
Manufacturing Area
 Manufacturing storage and support areas
 Dental training and operatory
 Administrative offices

Original Project
Introduction
 EXISTING
 CONDITIONS
 Design
 Objectives
 Mechanical
Alternatives
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
Straumann
USA
Renovation of 153,000ft2
 Complete airside upgrade
 No central plant changes

Construction May 2004 – May 2005
 Cost $10.6 million

Straumann
USA
Mechanical Systems
Introduction
 EXISTING
 CONDITIONS
 Design
 Objectives
 Mechanical
Alternatives
9 VAV AHU’s
 1 CAV AHU
 2 natural gas boilers

(11.3 MBH)

3 centrifugal chillers
(750, 500, 350 tons)

2 cooling towers
(750, 680 tons)
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
1st Floor
Mezzanine
Design Objectives
Straumann
USA
Introduction
Existing
Conditions

Educational experience
 DESIGN
 OBJECTIVES

Reduce annual energy costs
 Mechanical
Alternatives

Provide a lower 20 year LCC
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
System Comparisons
Introduction
Existing
Conditions

Airside

Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth

 Conclusions
Kevin Kaufman
Mechanical Option
VAV vs DOAS
Waterside
Chillers

 Construction
Breadth
 Life Cycle
 Cost Analysis
Straumann
USA


Direct-fire Absorption

Electric Centrifugal
Waterside Free Cooling

Series

Parallel
Straumann
USA
VAV System Advantages
Introduction
Existing
Conditions

Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth

 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option

Single system for
ventilation and
space cooling
Full air side
economizing
available
Lower pumping
costs than DOAS
DOAS System Advantages
Straumann
USA
Introduction
Existing
Conditions

Design
Objectives
 MECHANICAL
ALTERNATIVES

 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option

Reduced fan
energy costs
Smaller air-handling
units require less
space and are
cheaper
Decouples sensible
and latent loads
Straumann
USA
DOAS Rooftop Unit Zones
Introduction
Reduced from 10 to 8 zones
Existing
Conditions
Design
Objectives
Ventilation Air
Supply Air
VAV (CFM)
DOAS (CFM)
35,144
510,400
15,104
143,742
% Reduction by
DOAS
57.0%
71.8%
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
RTU-1
RTU-2
RTU-3
RTU-4
RTU-5
RTU-6
RTU-7
RTU-8
Straumann
USA
DOAS Design
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES



Radiant panel
capacity – 54 Btu/ft2
Space DPT – 55°F
Water MWT – 56.5°F
 Electrical
 Breadth
Radiant Panel (Sterling)
 Construction
Breadth

 Life Cycle
 Cost Analysis

 Conclusions
Kevin Kaufman
Mechanical Option
Ventilation rate – ASHRAE 62.1
Design Temperatures


Winter – 7.7°F
Summer – 90.8°F/73.7°F
Annual Energy Cost Comparison
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
Component
Air System Fans
Cooling
Heating
Pumps
Cooling Tower Fans
HVAC Sub-Total
Lights
Electric Equipment
Non-HVAC Sub-Total
Grand Total
Straumann VAV
$72,647
$64,415
$42,958
$17,916
$8,961
$206,897
$68,570
$423,845
$492,415
$699,312
Cost
Straumann
DOAS/VAV
$50,727
$62,839
$20,298
$24,035
$8,752
$166,651
$68,570
$423,845
$492,415
$659,066
DOAS Savings
$21,920
$1,576
$22,660
($6,120)
$209
$40,245
$0
$0
$0
$40,245
Direct-fire Absorption Chiller
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES


 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option

Reduce electric
load and demand
Natural gas
available on site
Possibility for
simultaneous
heating and cooling
Absorption Chiller (Carrier)
Chiller Annual Energy Comparison
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
Cost
Electric Centrifugal Chiller
Straumann
Straumann VAV
DOAS/VAV
Component
Air System Fans
$72,647
$50,727
Cooling
$64,415
$62,839
Heating
$42,958
$20,298
Pumps
$17,916
$24,035
Cooling Tower Fans
$8,961
$8,752
HVAC Sub-Total
$206,897
$166,651
Lights
$68,570
$68,570
Electric Equipment
$423,845
$423,845
Non-HVAC Sub-Total
$492,415
$492,415
Grand Total
$699,312
$659,066
Direct-fired Absorbtion Chiller
Straumann
Straumann VAV
DOAS/VAV
$72,647
$50,727
$107,264
$92,452
$42,958
$20,298
$21,720
$28,737
$13,779
$9,055
$258,368
$201,270
$68,570
$68,570
$423,845
$423,845
$492,415
$492,415
$750,783
$693,685
Waterside Free Cooling - Parallel
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option


Reject heat without a chiller
Must be able to reject entire load
Waterside Free Cooling - Parallel
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option


Reject heat without a chiller
Must be able to reject entire load
Waterside Free Cooling - Parallel
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option


Reject heat without a chiller
Must be able to reject entire load
Waterside Free Cooling - Series
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis

 Conclusions

Kevin Kaufman
Mechanical Option

Partially or completely rejects heat from
chilled water
Operates more hours than parallel
Requires more complex controls
Waterside Free Cooling - Series
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis

 Conclusions

Kevin Kaufman
Mechanical Option

Partially or completely rejects heat from
chilled water
Operates more hours than parallel
Requires more complex controls
Waterside Free Cooling - Series
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis

 Conclusions

Kevin Kaufman
Mechanical Option

Partially or completely rejects heat from
chilled water
Operates more hours than parallel
Requires more complex controls
Waterside Free Cooling - Series
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis

 Conclusions

Kevin Kaufman
Mechanical Option

Partially or completely rejects heat from
chilled water
Operates more hours than parallel
Requires more complex controls
Waterside Free Cooling - Results
Introduction
Existing
Conditions
Design
Objectives
Ton Hours
Free Cooling
Parallel
Series (55)
Series (51)
 Life Cycle
 Cost Analysis
591
591
591
0
33036
11470
769711
770465
769014
-754
698
800.0
Cooling Load (tons)
 Construction
Breadth
Ton Hours Series Total Energy Savings Compared to
Cooling
(kW)
Parallel (kW)
Cooling Load vs Wet Bulb Temperature
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
Straumann
USA
600.0
400.0
200.0
 Conclusions
0.0
0.0
Kevin Kaufman
Mechanical Option
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
Wet Bulb Temperature (F)
Chiller
No Cooling
Series Cooling (51)
Free Cooling
Chiller 2
Electrical Breadth
Introduction
Existing
Conditions
Design
Objectives
Mechanical
Alternatives
 ELECTRICAL
 BREADTH
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
Straumann
USA
Branch Circuit Summary of Alterations
Item
Breaker
Panel Id
Action taken
Wire Szie
Description
Size
5 Single Phase
5HL2
VAV Boxes
#14
15
Ciructs Removed
4 Single Phase
5HL2
FPB'S
#14
15
Circuits Removed
4 Three Phase
5HL2
FPB'S
#8
30-40
Circuits Removed
4 Single Phase
5HL3
VAV Boxes
#14
15
Ciructs Removed
3 Single Phase
5HL3
FPB'S
#14
15
Circuits Removed
2 Three Phase
5HL3
FPB'S
#8
30
Circuits Removed
6 Single Phase
5HL4
VAV Boxes
#14
15
Ciructs Removed
1 Single Phase
5HL4
FPB'S
#14
15
Circuit Removed
2 Three Phase
5HL4
FPB'S
#8
30
Circuits Removed
6 Three Phase
2MCC-1
VAV Units
#10 - 1/0 20-150
Circuits Removed
4 Three Phase
2MCC-1 DOAS Units
#12
20
Circuits Added
Freeze
6 Three Phase
10MCC-1 Protection
#12
Circuits Removed
Pump
Conduit
Size
1/2"
1/2"
1-1/4"
1/2"
1/2"
1-1/4"
1/2"
1/2"
1-1/4"
3/4" - 2"
3/4"
3/4"
Straumann
USA
Electrical Breadth
Introduction
Existing
Conditions
Design
Objectives
Mechanical
Alternatives
 ELECTRICAL
 BREADTH
 Construction
Breadth
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
Panel Id
5HL1
5HL2
5HL3
5HL4
2MCC-1
10MCC-1
Wire Size
2 sets of
500 MCM
Feeder Summary of Alterations
VAV
Breaker Size Conduit Size Wire Size
800A
3-1/2"
500 MCM
500 MCM
4/0
2 sets of
500 MCM
400A
400A
225
4"
4"
2-1/3"
800A
3-1/2"
#1
100A
3"
2 sets of
500 MCM
DOAS/VAV
Breaker Size Conduit Size
800A
3-1/2"
300 MCM
3/0
#3
2 sets of
250 MCM
300
200
100
3-1/2"
3"
1-1/2"
500
3-1/2"
#10
25
3/4"
Construction Breadth
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
Mechanical
Alternatives
Electrical
Breadth
 CONSRUCTION
BREADTH
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
VAV Electric Costs
Electric Panels
$29,010
Breakers
$15,313
Wiring
$33,537
Conduit
$249,455
Total
$327,314
VAV Rooftop Units
CFM
Cost
RTU-1
33,000
$24,000
RTU-2
33,000
$24,000
RTU-3
6,400
$10,400
RTU-4
33,000
$24,000
RTU-5
24,000
$17,700
RTU-6
24,000
$17,700
RTU-7
33,000
$24,000
RTU-8
33,000
$24,000
RTU-9
33,000
$24,000
RTU-10
33,000
$24,000
Total
$213,800
DOAS Electric Costs
Electric Panels $14,525
Breakers
$5,860
Wiring
$14,770
Conduit
$108,056
Total
$143,211
DOAS Rooftop Units
CFM
Cost
RTU-1
4,273
$11,513
RTU-2
3,328
$9,675
RTU-3
1,052
$6,550
RTU-4
3,089
$9,444
RTU-5
33,000
$24,000
RTU-6
33,000
$24,000
RTU-7
33,000
$24,000
RTU-8
33,000
$24,000
Total
$133,181
Straumann
USA
Construction Breadth
Introduction
First Cost Summary
Existing
Conditions
Design
Objectives
Mechanical
Alternatives
Electrical
Breadth
 CONSRUCTION
BREADTH
 Life Cycle
 Cost Analysis
 Conclusions
Kevin Kaufman
Mechanical Option
DOAS
VAV
AHU
Radiant Panel
Diffuser
Ductwork
VAV/FPB
Mechanical Subtotal
$133,181
$602,778
$17,520
$23,616
$0
$777,094
$213,800
$0
$99,595
$34,316
$116,239
$463,950
DOAS Additional
First Cost
($80,619)
$602,778
($82,075)
($10,700)
($116,239)
$313,144
Electrical
$143,211
$327,314
($184,103)
Total First Cost
$920,305
$791,264
$129,042
Initial Chiller Cost
500 Tons (2) 300 Tons (1)
Total
Electric Centrifugal
$191,000
$130,400
$512,400
Direct-fire Absorption
$392,000
$245,000 $1,029,000
Straumann
USA
Life Cycle Cost Analysis
Introduction
Existing
Conditions
Design
Objectives
Mechanical
Alternatives
Electrical
Breadth
Construction
Breadth
 LIFE CYCLE
 COST ANALYSIS
 Conclusions
Kevin Kaufman
Mechanical Option
Air System LCC
Air
System
20 Year Life
Cycle Cost
VAV
DOAS
$8,812,317
$8,479,052
Chiller Type
Electric
Absorption
Life Cycle
Cost Savings
First Cost
Annual
Cost
Payback
$0
$333,265
$791,264
$920,305
$699,312
$659,006
N/A
3.7 years
Chiller and Air System LCC
Air
20 Year Life
First Cost
System
Cycle Cost
VAV
$9,324,717
$1,303,664
DOAS
$8,991,452
$1,432,705
VAV
$10,431,686
$1,820,264
DOAS
$9,905,818
$1,949,305
Annual
Cost
$699,312
$659,006
$750,783
$693,685
Payback
N/A
3.7 years
No Payback
No Payback
Straumann
USA
Conclusions
Introduction
Existing
Conditions

Design
Objectives
Mechanical
Alternatives
Electrical
Breadth

Construction
Breadth
Life Cycle
Cost Analysis
 CONCLUSIONS
Kevin Kaufman
Mechanical Option

DOAS has a higher initial cost but has a
lower annual operating cost and can be
paid back in 3.7 years.
Absorption chillers increase annual
operating costs.
Series waterside free cooling adds a few
additional hours of free cooling but will
add more complex controls.
Straumann
USA
Acknowledgements
Introduction
Existing
Conditions

Design
Objectives

Mechanical
Alternatives
Electrical
Breadth
Construction
Breadth
Life Cycle
Cost Analysis
Conclusions
Kevin Kaufman
Mechanical Option



AE Department
Mechanical Faculty
Bruce Chappell
William McGee
Paul Petrilli




Straumann USA
Brickstone Companies
Justin Bem
Markus Benzenhofer
Questions?
Chiller Heater Feasibility
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
 MECHANICAL
ALTERNATIVES
 Electrical
 Breadth
 Construction
Breadth
 Life Cycle
 Cost Analysis

 Conclusions

Kevin Kaufman
Mechanical Option

Heating requirements: 3222 hrs
Simultaneous heating/cooling available: 733 hrs
Capable of meeting heating load: 507 hrs (16%)
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
Mechanical
Alternatives
Electrical
Breadth
Construction
Breadth
Life Cycle
Cost Analysis
Conclusions
Kevin Kaufman
Mechanical Option
Costs/ft2
Electric
Absorption
Component
Straumann VAV Straumann DOAS Straumann VAV Straumann DOAS
Air System Fans
$0.47
$0.33
$0.47
$0.33
Cooling
$0.42
$0.41
$0.70
$0.60
Heating
$0.28
$0.13
$0.28
$0.13
Pumps
$0.12
$0.16
$0.14
$0.19
Cooling Tower Fans
$0.06
$0.06
$0.09
$0.06
HVAC Sub-Total
$1.35
$1.09
$1.69
$1.32
Lights
$0.45
$0.45
$0.45
$0.45
Electric Equipment
$2.77
$2.77
$2.77
$2.77
Non-HVAC Sub-Total
$3.22
$3.22
$3.22
$3.22
Grand Total
$4.57
$4.31
$4.91
$4.53
Component
Air System Fans
Cooling
Heating
Pumps
Cooling Tower Fans
HVAC Sub-Total
Lights
Electric Equipment
Non-HVAC Sub-Total
Grand Total
Energy (MMBTU)
Direct-fired Absorbtion Chiller
Electric Centrifugal Chiller
Straumann
Straumann
Straumann VAV
Straumann VAV
DOAS/VAV
DOAS/VAV
1,564
1,229
1,250
356
156
4,554
1,509
9,326
10,835
15,389
1,093
1,202
616
455
155
3,521
1,509
9,326
10,835
14,356
1,564
5,838
1,250
439
246
9,337
1,509
9,326
10,835
20,172
1,093
5,072
616
542
146
7,468
1,509
9,326
10,835
18,303
Straumann
USA
Introduction
Existing
Conditions
Number of Hours per Wet Bulb Range
2500
Design
Objectives
Electrical
Breadth
Construction
Breadth
Life Cycle
Cost Analysis
Conclusions
Kevin Kaufman
Mechanical Option
Number of Hours
Mechanical
Alternatives
2000
1500
1000
500
0
WB < 30
30 < WB < 40 40 < WB < 50 50 < WB < 60 60 < WB < 70
Wet Bulb Temperature (F)
WB > 70
Straumann
USA
Introduction
Existing
Conditions
Design
Objectives
Mechanical
Alternatives
Electrical
Breadth
Heat Exchanger in Parallel
No Cooling
Free Cooling
Chiller Cooling
Total
Conclusions
Kevin Kaufman
Mechanical Option
5051
2
3707
8760
0
591
904743
905334
Fan Energy Chiller Energy Additional
(kW)
(kW)
Pump (kW)
0
50
103773
103822
0
0
665889
665889
Total Energy
(kW)
0
0
0
0
0
50
769662
769711
Additional
Pump (kW)
Total Energy
(kW)
0
0
934
0
934
0
50
15635
754780
770465
Additional
Pump (kW)
Total Energy
(kW)
0
0
324
0
324
0
50
14184
754780
769014
Heat Exchanger in Series (55F)
No Cooling
Free Cooling
Series Cooling
Chiller Cooling
Total
Construction
Breadth
Life Cycle
Cost Analysis
Hours
Ton
Hours
Hours
Ton
Hours
5051
2
108
3599
8760
0
591
33036
871707
905334
Fan Energy Chiller Energy
(kW)
(kW)
0
50
3222
103773
107044
0
0
11480
651008
662487
Heat Exchanger in Series (51F)
No Cooling
Free Cooling
Series Cooling
Chiller Cooling
Total
Hours
Ton
Hours
5051
2
38
3669
8760
0
591
11470
893274
905334
Fan Energy Chiller Energy
(kW)
(kW)
0
50
1134
103773
104956
0
0
12726
651008
663734